Can't Generate Fillet. Workarounds?

[erikscott128]

I'm trying to make a 0.25" fillet/round at the edges shown here. It can't seem to find a solution to anything greater than about 0.07, which is much too small. There must be a fillet here, and it must be roughly 0.25". I know this kind of thing must be a frequent issue for people, and I'm interested in hearing some potential work-arounds that don't involve re-designing the whole part for what feels like the millionth time. 

Thanks in advance

[g-andresen]

Hi,

A reliable statement on this question requires an analysis of history.
Therefore, please share the design.
Fillets can be made difficult or even impossible, e.g. by previous actions.

Günther

[TheCADWhisperer]

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@erikscott128 wrote:

.... re-designing the whole part for what feels like the millionth time. 

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Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

Someone will redefine the geometry for you.

[erikscott128]

I have attached the file. The design history is fairly involved considering the complexity of the shape. The issues seem to be due to the lofted shape of the main part of the grip. There are certainly areas where it may be more complex than necessary simply because I may not know all the right techniques. 

I recognize that something like this could be accomplished with the sculpt/freeform toolset, but because I'm working to a number of known dimensions, I figured solid and surface modeling would be the way to go. 

Thanks for any help