Hi Ron,
Yes, there were a few problems. Once I had to scale to 1/10, separate, then join after a fillet had left the object as a Joined srf instead of Solid.
Another time I was trying to create a fillet which effectively blended to 0. I couldn't get the Fillet Set feature to work so I created a 'stop' element which allowed the fillet to be created BEFORE ending in 0. This was not optimum, but based on the overall complexity of the model, wasn't so bad.
FWIW, the whole model was a solid at the end. Impressive how MoI could keep up with so many boolean, fillet and chamfer applications.
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