seems so simple, but...

 From:  Michael Gibson
5400.7 In reply to 5400.5 
Or also another fillet technique that can work in cases where the regular edge-based filleter fails is to break the model apart into individual surfaces, and then select 2 surfaces at a time and do the fillet.

That will perform a surface/surface fillet operation which can sometimes build some fillet surfaces where the edge-based filleting mechanism can get confused.

- Michael