Hi scott, 2 adjacent faces that are coplanar fragments of the same larger plane can be merged using boolean union but there isn't currently an automatic way to merge together 2 extrusions.

So for the time being to merge them you would need to delete the current fragments and then make a larger extrusion going over the full extent and then join that in.

I've attached a version where I've done that, it should be easier to fillet this one.

- Michael

Thank you for the 'instantaneous' reply.

After perusing the forum messages, I wanted to ensure I didn't overlook some of your magic. For now I'll focus on streamlining my workflow as the best solution.

Thanks again.

Scott