What kind of operation are you using to do the final cleanup? Any chance you can attach the file in question, or at least a screenshot including the CAMWorks operation tree? You can PM me if its too sensitive to post here for all to see. It may be a matter of using the wrong type of operation for what you're actually trying to do, or it could be something as simple as having WIP machining or gouge checking turned on. I've been in this situation probably hundreds of times with CAMWorks and can usually find a way out of it!