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Is there a way to create a chamfer on a modeled thread that would blend/match the lead in and out of the thread instead of staying a complete chamfer? (see picture)
I think this is an order of operations issue. Create the thread as not modelled, apply the chamfer, then turn on modelling. The reason your seeing the artifact in your example is that the thread is actually starting after the chamfer. Personally, I'd like to see a chamfer allowance (and lead out) in the Thread dialog, this would allow me to pass chamfer and lead out to the canned cycle.
