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My 2 cents is:
thicken works and does provide a good tool for defining constand thickness parts (we make deep draw sheet metal stamped parts).
If a thicken feature fails try "options>exclude surfaces" and see which surfaces, when excluded, allow the thicken feature to work.
Make sure all the radii are larger than the thicken feature (only matters when thickening the radii inward)
The biggest help when thickening complicated surfaces is play with model accuracy trying to get the tightest possible accuracy.
Good luck,
Ross H. Liberty
Factory Pipe
Apologies, I put my earlier response in the wrong thread . . . newbie.