Hi Marco, it's difficult in general to do G2 blends on things that have sharp corners in them. What happens is the blend sees the sharp corners and then will build a blend between each separate pairs of edges, and the G2 option means to make the blend match the curvature of each surface and like in your case here each surface has a different kind of curvature and so the different blend pieces are matching different things and so won't necessarily meet up with their neighboring blend piece.

So it's basically just something that goes along with trying to blend with sharp corners, especially with doing G2 blends.



I've attached a solid result - the steps I did for that were to first trim the each blend surface with it's neighbor to cut away any overlapping portions. To do that use Edit > Separate to break the blend into individual surfaces, then select a pair of surfaces and run Edit > Trim and at the prompt that says to select cutting objects just right click or push the "Done" button to go into mutual trim mode where the surfaces will trim each other, then at the next prompt that says to select which pieces to discard, switch the mode to "Keep" and then click on the large surface pieces. That will discard the overlap pieces and get the edges closer to each other.

Then in order to join things into a solid I had to scale the object down by 1/10 in size and then do the join.

- Michael