Hi Anthony, also another problem is that one of the surfaces is not of good quality, it has some bunching and bad forming in it:






Trying to build a surface where the generator curves change a lot and compress together or go to a sharp point like that is not good - that will make for problems in the surface shape, like possibly small folds near that area and just not a clean shape to it.

Shaping problems like that will also tend to cause difficulty in filleting.

For something like that, instead of surfacing directly to the outline you usually need to build a larger more simple sheet and then trim it with surrounding pieces instead of trying to "patch in" to a non-regular boundary like that.

- Michael