Hi BurrMan,
you wrote "The thing to note is I do the larger fillets first, then work down to smaller ones..."
In my case its work only in opposite direction. In many case, I don't understand the fillet function.
I think we can not generalized it.

Fillet1 works from small to lanrger fillets.


fillet2 try to make fillet from large to small. The small fillets are "corrupt" (not sure with my english ;) )


Scene file

Another try to make 2 fillets on to the same object. One edge can't fillet with 0.1. the other edge works fine with 0.1
the edges are clean and only one segment.



Cheers
Jörg