Lessen learned... I revolved both "faces" to 360 degrees. It was difficult to separate the inside surface into 4 pieces. There are some trim issues when trying to separate a single quilt. Therefore, you will find the outside is fully rotated and the inside is only a quarter. This resolved the feature failure issues when trying to merge the part into one.
This is a very stylized part. Both surfaces are curved. Pretty simple once you get past the Creo limitations.
Some stylized features may have been better using toroidal bends and other fancy wrapping techniques. But this one is fairly true to the original. It is always difficult when you don't have the original intent... a parametric reference, for instance.