Hi chippwalters,

First of all i wish to thank you for your suggestions and your considerations.

I tried to follow what you said, but unfortunately without achieve the wanted result...

I know that this, is nothing more then a design experiment and a way to better know Moi's tools, but i'm hard headed :
and i made the experiment that i attach to this reply.

The file that i'm posting here, certainly will never pass any surface continuity test,
but i tried to go in a direction that could be the right one.

First of all i resized the original chair to be 30x bigger, just to have a more realistic size.

In the .3dm file, the object named "Chair1" is the chair with the smooth caps,
while the object named "Chair2" is an attempt to make a some sort of "manual" filleting.

I made the, more or less, smooth cap of Chair1, with the help of Blend and Sweep tools.

I hope that you or Michael, or anyone :), will have the patience to find a better solution, if it exists.

Thanks a lot and have a nice day,

Marco.