For literally YEARS now, I have been trying to make decent 'expanding radius' fillets (like those on the Supermarine Spitfire) on wing/fuselage junctions for both full-size and model airplanes. I have tried every trick that I can think of without success. So, I thought I'd throw it out to the general audience in hope that someone can show me how.

Attached is a file for a new Q-40 model race plane (AMA event #422). It is loosely based on the AR-6 "Endeavor" Formula One race plane at Reno, but the model is "cartoon scale" to meet the event requirements. It is the intent to use a 3D CNC mill to cut out the male plug from REN board and then pull molds off of that. The wing and horizontal tail plugs have already been cut but I need to finish the fuselage. The fuselage plug should have the wing saddle removed, and the fillets added.

Any thoughts or help would be appreciated.

Hi Gary
Can you zip and upload?
Tim

Tim: I tried that too, and it still didn't work. Obviously I am doing something stupid. It's not a big file. I emailed it to your evo-soft address, perhaps you can figure out how to upload it.

On a personal note old friend, my wife and I are building a new house near Lake Weatherford, and it turns out that we are building just across the street from John Bruce and wife. What a small world to move, by chance, next to someone that we both worked with over 35 years ago...

Hi Gary
I was able to get a 0.2 (up to 0.5 in some areas) inch variable radius blend to work if I split off the trailing edge.

The convexity and end capping in that area is too complex for ACIS to blend. At the split, I assigned a variable radius value of 0.01.

Since the variable radius tool only works on solid objects, you will need to boolean the fuselage surface to the wing to get a solid object. Be sure to change direction of the surface to get the proper material direction.

I like your use of polyconics, makes a nice fuselage!

*>>the street from John Bruce and wife.
Be sure to say hi to John from me!

Tim