Hi Gary, then some other problems are that some of the pieces that look like they should be tangent are actually a bit off.

Do you have your original curves that you used to create this object? If I could check those out that may help me to give you some tips.

For example this area here:



That is not smooth at that juncture there - the curved arc piece on the right-hand side does not come to a full flat tangent, it has an ending tangent that looks like this:



That kind of thing where you've got 2 pieces that are are not smooth but coming within 5 degrees or so of being smoother are difficult for filleting to handle. It's a lot better for such things to be more accurate to be tangent where they meet. Anyway, that's probably what is causing some fillet problems in that particular area.

- Michael