Hi Jeff,

> Since the fillet engine can't change radii I was thinking of
> using a sweep or loft to do the areas that transition from
> 7/16" to 1/8".

Yes, you'd need to do something along those lines to build a surface for that part.


> The bulging comment was referring to the circled section. This
> used to be flush before I cut, filleted and glued back together.
> Now it looks like the main piece grew.

Hmmm, yeah it looks like something was a little misaligned there, making that little shelf area.

It's hard to tell exactly what went wrong just looking at the final result here - if you possibly have some of the previous stages of the model that had the pieces you were cutting and gluing together, that would be where to look to see if some piece was not quite exactly aligned with some other piece being cut, making a little shelf like that.

It is possible to do some low level repair on things to fix problems like this, there is a tutorial on that kind of object repair techniques available here:
http://moi3d.com/forum/index.php?webtag=MOI&msg=446.17

- Michael