Found it! illegal geomery! It has one of these hard to find bugs where the edges arent merged because on the other side there s 2 edges and on the other 1 causing a gap smack in middle of where the boolean happens. Its akin to a nonmanifold shape thats not possible in reality.
time for debug 2 minutes 28 secs.

se there are 4 of thees eoccourences in your modell. the face thats seleced is 5 sided (it should be 6) and has 1 ege on the boundary while on the otherside theres a 2 edged side now the vertice is not connected to the face. Causing a infitesimaly small gap between the faces (actualy no gap at all is a s bad!)
Be carefull with your geometry!
Hope this helps you in the future. its easy to fix tough just use the edge split tool to make a axxtrra edge here there (you can then delet the edge as long as you merge vertices). This was apparent from the way your smooth worked but i mistook it for a normal issue.
Normaly you can spot theese with the custm border edge display.
fixed a blooper in last paragraph