Very sharp corners and fillets

 From:  Michael Gibson
4000.4 In reply to 4000.1 
Hi Jim, so the problem seems to be that some of the surfaces of that little pocket piece were not close enough to each other to be joined into a shared joined edge which is needed to do an edge fillet.

The problem is in these edges here:

If you zoom in a bit and hide the faces, leaving only edges to be displayed, you can see that there are actually 2 separate edges in those areas instead of one common joined edge between the surfaces there:

So in other words, it's kind of like a gap or hole in the model in that spot, the edges are not joined into a single unified edge right there.

So probably that will need to be repaired, I'll take a bit more of a look in a minute here.

- Michael