Solved
you have overlapping geometry. An advantage of creating the sketch in the feature/extrude is you will get an error when you try to complete it. You don't get this in the sketch only. See below for where the extra line was.
I would recommend breaking this up into a few sketches, extrude the outer shape and then extrude the t-slots, etc. trying to cram a bunch into one sketch becomes unmanageable at some point.
 - PTC Creo Parametric.jpg)
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