Hi Lana - the tolerance in this file is .01 units - too close to the fillet radius of .05. I would model this starting with a .001 or possibly .0001 tolerance and things will work a little better.
If I Explode your object and RebuildEdges then look at how things join up I see this:
It is not a large gap in numbers, but you can see it is proportionally pretty large. More on tolerances here:
http://wiki.mcneel.com/rhino/faqtolerances
@Lana1 - there is one more aspect to this - yes, starting from your primitive input objects and the file tolerance at .001 before you Boolean/trim etc, , things work better BUT, the pipe has a seam in the long direction and as is, that seam dives in and out of the football shape, which means that when you BooleanDifference it from the football, there are skinny little slivers of surface where the seam approches the larger surface, like so (red/blue):
The upshot is that FilletEdge cannot properly trim in these areas - FilletEdge does not know how to jump across the red surface where it is skinny and trim the blue one instead. I do not see yet how to adjust the surface seam, SrfSeam command, on the pipe so that it stays outside the football all the way around. The workaround is to accept what FilletEdge goves you and then ‘Explode’ or ‘ExtractSrf’ the fillets and neighboring surfaces, and use the fillet edges to trim the surfaces that `FilletEdge’ missed.
@Lana1 - here’s a way to model this so that the seam in the pipe is forced to stay on the outside - the key is to use ‘Sweep1’ of a circle oriented around the path curve and inside the sweep process, choose Roadlike Front and when the UI asks you to place the seam, make sure it is outside the football. The Roadlike option will ensure that it stays there (outside)
SwordHandle2Forum_PG.3dm (422.9 KB)
-Pascal