Hi Gary, so it sounds like you already know what the problem is, but just in case yes it is the block didn't quite go far enough to meet up with the edge from the rounded piece:
So instead of there being one edge there, there are 2 edges that are a very small distance away from each other - that's another thing that is bad for filleting unfortunately.
But your model in this case is a lot closer, I'll see if I can tune up that one spot.
- Michael
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