a quick video demo if a useful workflow when fillets fail.
enjoy!
Excellent tips! In my experience - the moment a fillet command fails, I simply go straight to this method. When I was starting, I’d spend so much time trying to get fillets to work in tricky situations like this, when it’s often faster to simply Pipe, Trim and Blend and move on to the next task.
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FilletSrf is also a good way out much of the time, and it keeps everything a true fillet.
-Pascal
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You’re videos are great, Kyle! I like how you always come up with neat tricks or strategies to approach stuff!
Right - it takes multiple doses, but I just mention it keep that option open in case it needs to be a rolling ball fillet for some reason-
-Pascal
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ah, got it… as always you are the man…
A suggestion. Can you provide a model or the part in question , so anyone can try to follow along or use a different method? Other than that, videos that can help in sticky situations are great! Please keep them coming . —- Mark
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I cannot, sorry… it’s on a file from an old client
@theoutside You know, Mark made an excellent suggestion. Not only could the user follow along on the same part you are demonstrating with, but he/she could also examine the part in detail to understand the characteristics that lead to the problem.
Certainly if you are generous enough to make the video in the first place, just a little more generosity would let you extract the culprit feature from the customer’s private file, no? 
Presumably the part got to the initial state you show because the modeler filleted the base shape edges first, then booleaned the chamfer into the fillet? I guess when I get a chance I’ll experiment with alternative constructions like booleaning the chamfer before doing any filleting, the messing with the order in which the fillets are applied. Of course, as you mention, a real purist would never put a chamfered hole so close to the edge in the first place. 
Bottom line: Great video and very handy technique.
Nda is Nda… can’t share it sorry… I got permission to make the video, but can’t share the part. This technique is useful for any situation where fillet fails… Also see Pascal’s note above about filletsrf and distance between rails.
correct, fillets were added 1st them the chamfered hole added later due to a fit requirement of the fastening system. Sometimes you have to make it work with what you are given…