Circular pattern error on fillet feature

[carlossommer1]

I'm following a training video https://www.youtube.com/watch?v=H80Kc-E_NSY&t=41s 

The problem starts at 3:56 where he creates some fillets on a rib of 1.25mm. This gives me an error where it is unable to create part of the fillet. If I make the fillet 1.22 or less it works fine. But than when I goto the next step and create the circular pattern, it errors out because of the fillet. What I fond is that if I keep the fillet .9mm or less it works, otherwise I get an error. Why is he able to do it at 1.25mm and I'm not? 

[wmhazzard]

It looks like for some reason the plane at an angle is being created 2 degrees off from normal to the XZ plane, that is creating odd surfaces at the bolt hole. I set the plane at 92 degrees and the fillets and pattern work. I don't know why the plane is created that way. 

[TheCADWhisperer · Accepted solution]

@carlossommer1 

Your model does not match the original.

There is also something else going on here that I haven't quite figured out - the "Lip" that I referred to isn't even symmetrical relative to the center of the part?

@jeff_strater 

This is an interesting one.

I can't figure out why Extrude3 did not come out symmetric along that intersecting edge with the fillet?

[g-andresen]

Hi,

Make sure that the profile-defining circle is concentric so that everything runs like clockwork.

Screencast

günther

[carlossommer1]

Dumb rookies. I figured it was something I did but was not able to figure out what. Thanks.

[wmhazzard · Accepted solution]

It looks like a bug with the projected line from the chord length fillet. If you delete the projected line in sketch 3 and replace it with a projected line from the bottom of the plate, the extrude is smooth.