Hi scott, 2 adjacent faces that are coplanar fragments of the same larger plane can be merged using boolean union but there isn't currently an automatic way to merge together 2 extrusions.
So for the time being to merge them you would need to delete the current fragments and then make a larger extrusion going over the full extent and then join that in.
I've attached a version where I've done that, it should be easier to fillet this one.
- Michael
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