Hi Jim - that one edge - I don’t now how to describe it, it’s this one:
has a varying angle between the faces there and they are not consistently increasing or decreasing, they wobble a bit - my guess is this is one reason the fillet is tricky there - the faces become almost tangent and then diverge again. It looks to me like you’ll need to hand build the end of that fillet.
@bigjimslade, Also, your file tolerance is .01, much to fat for an object that requires .05 fillets… This should have been built at .001 at most, I would say.
Problem79.3dm (1.0 MB)
Here’s one where I think I have straightened out the curves (which were originally created in another program).
I still get the same problem.
I did not reset the tolerance in either of the files that I copied this part to for uploading. I am using 0.00001. There’s a lot of really small stuff that goes on this part (not shown here).