Hi Don, really your revolve is looking pretty good. It's possible to use that and make it connect up better to the main piece.

The way you would do that is by putting in some cutting lines and using Edit > Trim to open up some empty space between the pieces like this:





Then select the 2 edges and use Construct > Blend to make a smooth blend surface in the empty area. You kind of need to leave enough empty space for the blend to fit well and be relaxed. If you make a space that is too small it will tend to accentuate any bending in the blend surface. Then to finish it you select the pieces and use Edit > Join to combine them:







- Michael

Hi Don, and just to clarify for Sweep - it is possible to make a rounded tip with sweep which you do by having 2 rails that meet up at their tips like this (shown here with one selected so you can see how they are formed), usually you set this up by having a smooth piece there (I used curve blend in this case) that you then trim at the tip:



Then also another piece for a sweep that will be collapsing down to a point at the tip like that is you need to make an additional profile shape before the end. Usually a circle or ellipse to even out the shapes as you approach the collapsing down spot. If you just directly try to collapse a profile with variations in it, those variations will tend to be accentuated. Basically a good rounded tip should be sphere-like in the area around the tip, it won't look good if it was still trying to have the other profile shape right in the area round the tip.

So then you select profiles like this:


And then do a sweep and then select the rails:







- Michael

Great stuff Michael! Thanks for sharing your procedures.