It's been at least a week since the fillet engine has bitten me. =P

 From:  BurrMan
4156.3 In reply to 4156.2 
I deleted the verticle surfaces of those letters, then ran a loft with the "straight" option, then rejoined them and they would fillet at .008.. It did work much better when scaled to 10X.

In each of them, one of the little corner patches of the fillet, would come out with a poorly defined surface and I would dlete it and then fill it with a sweep function, then rejoin to a solid....

FYI