I think at this point you might want to better define what your end goal is - sweep/skin can do some things, but the Copy SOP can do others…
what I think you're heading towards is a modular building kit where you have wall sections (with different structures, different detailing etc) and then you want to have a curve (or path that defines corridors, intersections, turns etc) and in-between these you'll want bulkheads, doors, airlocks etc etc.
as fun as what you have so far is, and it's demonstrating some tools and workflows, I think you'll very quickly build yourself into a corner - you'll have a cool but very complex system that isn't easy to use or change.
so instead of figuring out how to have better transitions and airlock type sections between the swept sections, you might be better off building the types of sections you want as separate modules (you can still use some of the techniques you've already tried), then combine those modules with a more flexible system (the multiple merge trick is fun and useful - but imagine having 15 different section types and then trying to add a new section at a specific spot…hard or impossible!).
the attached image is a quick floor plan that shows the different types of modules you might build (all straight for now but curved modules are easy enough) - and module C - corridor - might be just one type of corridor. Or you can have a “C”, then some kind of section that fits into a corridor then another type “C”…etc etc…
if all the sections are built with the idea that they should be able to connect to most or all of the other sections then you can very quickly build up a modular kit. And each module can use the tricks you already know - if applicable.
to answer you specific question about a “…blockhead or a beam doing a hard cut off, say for a door to be framed in?”
you might build your corridor sections with optional ends - so if the “C” section connects to a door it might use EndType-01, or if it connects with an airlock it would use EndType-02…
I hope this has helped a bit.
this type of stuff is used a lot in games…
https://www.artstation.com/contests/the-journey/challenges/3/submissions/538 [
artstation.com]
http://wiki.polycount.com/wiki/Modular_environments [
wiki.polycount.com]