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Can't merge parts to a shell


Hi

I am drawing an engine casing for a steam engine. 

I am trying to add various features to the shelled casing.  Specifically, I am trying to add a flange for a cover plate.  The problem is that I can't merge the flange and the casing to form a single part. Also, if you look up inside the casing, there are two bushings.   I can't merge these either.

I get the error message:  "Cannot merge bodies.  Operation failed because the faces and edges would combine in a way that does not form a valid solid or surface."

When preparing for this post, I chopped off most of the part to leave the part of the casing with the flange.  When I did this, the flange did merge with the casing. 

A dropbox link to the full unchopped  file is here:

https://www.dropbox.com/s/2649g3ttdteke7u/Engine%20Casing%20Full%20Size%20thick%20fully%20shelled%20casing%2020200119.jpg?dl=0 

I have tried a range of different methods of making the penetration in the casing for the flange, but none work. 

Can someone please advise on how to troubleshoot this problem and how to merge the parts?

Dazz

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