Basically,
I try to avoid the extrusion issues and the sectioning protocols whenever possible... for the very same frustrating reasons you describe.
Instead focusing effort on the uniqueness of the curvature using the simplicity of lines & arcs with the basic Chamfer/Fillet to get the shape right.
Working in the isolation of the Group allows for unlimited zoom.
Then , adding the other line elements with joins prior to composing it all. This process will continue as each of the sectional profiles is produced.
Finally , extrusion or conversion to NURBS> Lofting or ExtrudeAlongPath to finish the shape.