Hi Gary, well right off the bat I can't see how a fillet of 0.1 is going to fit in some areas.

For example this little line right here:





Is only 0.06 units long, so there's no way for a fillet of 0.1 units to fit in that space.

I would normally start trying to find which areas are causing fillet problems by going through and filleting some smaller isolated pieces of the model first, but the first area that I looked to do was that little piece where the fillet just would not fit.

Aside from that, there may be some problems with MoI's fillet engine trying to handle the sort of concave corners that you've got here. I'll keeping looking at some other areas here...

- Michael