Hi Kevin,

> This is what I have done in my model

No, not quite - what I was talking about there would be using the kind of "larger independent component" parts like I was showing earlier. You were mentioning that a fillet would not do the right thing that you wanted where the pieces connected - you would use a sweep in there instead of the fillet, kind of like this:

The 2 larger components booleaned together:



Then since a fillet does not give you the right shape, you would trim away some parts to make a gap:



Then the sweep would fill in that gap making a kind of custom fillet - the sides of the gap would be the rails for the sweep and you would put in some cross-sections to control the shaping of the blend to get more control over it.

That would be the way to solve your problem of a standard fillet not being what you wanted in between those 2 pieces. But it will be a while before that would work with continuity in MoI.

- Michael