Thats a cool way...I love booleans but havent used them for a while. Another really quick way I have made a video for you mate. At the end I thought of edge loops but it didnt work...some edge extrusion is still needed etc. This is just another way of getting around Maya..there are 1000's. This can also be applied when a boolean doesnt work...sometimes I just extract a face...do the extrusions and then snap the verts back together. Hope all of these suggestions help you out mate...and yes I only just saw/thought of it looking at yours dave...hmmm me thinks more lager is the order of the day!

cheers bullet

https://dl.dropbox.com/u/4090628/stonedinc.wmv