Hello Michael,

Sorry to keep bothering you with the same basic issues.

In order to blend the one fillet radius into another I'm going to go about it with two different methods to learn both. Here is the first method and the weird problem I'm getting.

The basic process is that I took the body shape and filleted it with both radii.

I swept the blend curves, trimmed the small piece that will have multiple radii.

Then I was going to weld (union) them together.

Here are the two blocks I built.




I then overlayed them like this and performed a UNION to weld them together.




Unfortunately I got some weird results on one side. I got a zigzag edge after I unioned the pieces. I couldn't see it in the before blocks.





Here are some closeups of the zigzag and a closeup of the geometry that looks like it may be causing the problems. A mismatch of the pieces perhaps?









Unfortunately, I don't know how the zigzag was created since I copied curves from both blocks to make the trim curve. I'm guessing the filleted process may have moved something out of alignment.

Any guesses suggestions.

Thanks as always.

Jeff