It depends on what version you perform the booleans. Boolean operations were significantly improved in C3 and after. One of the best tips I can give for boolean operations is to have the same sized mesh for the places where the obects intersect (where the boolean will occur). That way, the sizes and spaces for the newly generated mesh don't have to generate too many new vertices. Keeps the computations down and makes for a cleaner cut. -Kix

-Kix