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Ben, Can you use pdf995 for Plotting and Printing? I thought this enabled you to set up a Windows printer and therefore you can only use this utility when selecting File -> Print.

While we're on the long shots.... Any spaces in that server path? UG has also been know to be sensitive to spaces in paths.

Not sure if this helps, but to answer your question: "Does anyone know of a way that I can revolve the solid body so that the outer most features of the part are captured into one solid body so I can section it or revolve it into a 2D profile?" If you have a Motion license you can do this...

Take a look at your Assemblies Report when this happens to see if this gives you an idea of what is happening, i.e., parent reference sets, loaded status, etc. This does seem strange behaviour, especially if it's intermittent. You mention a global change to ref sets... if a parent assembly...