Hi Warren, it sounds like you've got this figured out now, but just in case:
> I guess the problem lies in how I created the outer scallop shape in the first place then?
> That vertical line seems to be the fun killer. Is there a way to remove it or does it all come
> down to how I create things in the first place?
The vertical line is a problem because the surfaces on either side of it are not smooth to one another, they come to about a 15 degree angle and these kinds of shallow angles where things are sort of close to being smooth but not quite actually smooth tends to make things difficult for filleting.
It isn't necessary to totally remove those vertical lines, but what you want is for the surfaces on either side of it to be tangent to one another rather than only slightly creased to one another.
> Basically, get the first steps right or it's never going to work?
Yeah it helps avoid a lot of problems if your original curves that were extruded were tangent to one another.
For filleting it's usually best if things meet at a sharp angle to one another or are smooth where they meet. Things that are just kind of close to being smooth but not actually smooth (like say 5 or 10 or even 15 degrees off like in your case here) make things a lot more difficult for the filleting mechanism. That's because anytime you have pieces meeting sharply to one another at all the fillet segments that follow them will not line up directly to one another and will need to be trimmed or have corner juncture pieces put in place, and when things at at shallow angle the various calculations that go into that become more difficult.
- Michael
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