Hi Burr, I can't really help you myself with the "how to machine it" part. But when you were asking about which part was variable since when you viewed it from the top it had some skinnier and wider areas to the fillet, that made me think a bit about this alternate way to do fillets.
I'll attach a model here that has this alternate way of doing the fillet, if you want to check it out.
This method of creating the fillet uses a different measurement to control the fillet.
Imagine that this is a cross-section of the fillet piece between 2 surfaces:
With constant distance, instead of controlling the fillet radius you instead control this distance value for the distance between the rails:
However, this does mean that the radius is variable and is constantly changing, the radius grows or shrinks as needed to maintain that distance. So I don't know if it will help out in this particular case or not, maybe not I suppose. But if would, I'd be interested to know!
The geometry library that I'm using has an option for doing constant distance filleting but it seems to be somewhat less reliable than the regular fillet mechanism though.
- Michael
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