Hey Magic,
Very nice again.. You present your workflow well...

I wanted to inject something.. regarding the switch.. You wanted to soften the edge and had some failed commands??? (Not suggesting I dont like your switch)

When you make the initial "star" shape, dont fillet it yet.. Go ahead and add your thumb extension and create the solid, then attempt to add the fillet to the solid..



Surely it can depend on the shape too, and not succeed, but "pre-filleting" the curve, will pretty much ensure only a very tiny fillet will fit...

Great stuff again...