Hi Magic,

""""""Burr, thanks! But that's what I did: (??) I made the star wheel with filleted corners, unioned in the thumb extension, extruded the shape and... all sizzle and no steak. :-("""""""""

Burr wrote:

Make star wheel (Note, NO filleted corners on star), Union thumb extension, extrude the shape, "FILLET SOLID NOW".....