Hi rodney, this is definitely a step closer, but there are still some areas in it with little tiny edge and surface fragments, which does not usually make the filleter very happy.

For example zooming in on this point here:



You can see there is a little tiny edge fragment there and a little surface piece as well:




From the viewpoint of the fillter, those are highly complex and difficult areas to resolve correctly during the various fillet calculations.


Also the "seam edge" of the tubular surface is also coming into play:



You probably want to make that tube with the Twist = Flat option so that you can keep the seam edge (where the surface is closed and curls back to touch edges like a piece of paper rolled into a tube) from wandering around and making more junctures with other edges than necessary.

I'll mess around with it a bit and see if I can give you any quick tuneup ideas, but this is something that I'd consider a very difficult case, the geometry is going to need to be as clean as possible (meaning the fewest number of edges and pieces) in order to have a chance.

- Michael


EDIT: Looks like Burr beat me to it, thanks Burr! :)