boolean union strangeness

 From:  BurrMan
7945.13 In reply to 7945.8 
""""""""""""""""""So here's the file without any fillets. Does anyone have suggestions on how to add 6-8mm fillets on the yellow highlighted areas for each spoke? The multiple tapered sections seem to confuse the fillet engine, and what works for one spoke *does not work for all*."""""""""""""""""""

There are a few things with this file I didn't like. Some surfaces were not smooth? (Separate outer surface of inner hub and zoom in)

Mostly though the fillets failed because of a slightly twisted, out of plane surface structure which made for terrible fillets. Here is a video where I rebuilt objects.

at beginning I planar (flat snap) spoke objects. Fillet then works ok at 8mm.