Hi Gordon,
re:
> Also though, I would like to leave all the elements separate but add a fillet to each edge and then join them
> together. I assume this is possible?
It is if they are aligned better, you would need to avoid having the gaps and overlaps shown above to get them to combine together.
Make sure you are using object snaps when positioning things so that you get things placed accurately, don't just move things around so they look visually close.
It looks like the smaller end cap lines on the left sides are not quite vertical. You can get that tuned up by turning on control points, selecting the end points and squishing it down to get "flat" snap:
Or you can also use the Transform > Align tool for that.
But also the top and bottom curves are not exact copies of each other, they're slightly different so when you try to stack them up they don't match up all the way. You would want the top and bottom to be exact duplicates so they'll line up with each other when you stack the pieces up.
- Michael
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