You can see the result with the edges hidden. Now I could use 'Network' with three true cross-sections between the two objects. I then projected the red curves onto both objects and did another 'Blend' between them. This is using 'Blend' with curves only, not surfaces. I then made the blue curves and did a 'Blend' between them. Then I copied the other part and aligned them. First, I copied the cylinder where you had projected the curve and cut the hole. _As to your fillet problem, this was simple. In any case, when I project lines and adjust the endpoints, I eliminate the errors. In theory, the points should work out right, but in practice these errors keep coming. I can't tell you why we get these errors. This led to all sorts of problems, so I had to find a way to work so that I only had one true endpoint or intersection. Which one is the "right" one? In some cases, I ended up with three or four "endpoints". This saves a step, so why bother to project the curve and move the endpoints? Well, I started out doing it that way, and I found that too often I ended up with spurious endpoints that is two or more "endpoints" very close together. In many cases, you might not project a curve, but instead, in one of the orthographic views, cut the surface directly. This is how I produce more than 1400 surfaces without errors. How could I avoid these? I found that the best way was always to begin with a line, adjust the endpoints, then 'Trim'. When I started with MOI, I was doing what I thought should work, but when I zoomed in, I found too many mismatched endpoints. Using 'Blend' to make cross-sections, and then using 'Network' to build the fillet eliminates those errors. Also, as I said, 'Blend' will frequently mismatch the edges of fillets, where more than one 'Blend' is required. Only then do I use this line to 'Trim' the surface. This eliminates a thousand errors that prevent the edge of one surface from matching the edge of the next surface. Then, I move the endpoints of that line to the intersections of the surface. Let me say again that my method is to 'Project' a line onto a surface. Then the whole cylinder was one joined-object. That surface was a simple one and I redid it in a few seconds. Only one had a problem! Think about that: More than 1400 surfaces in this model and only one problem. I also eliminated all the 'holes' (screw holes) which were open on the bottom. To change the model for 3D printing, I eliminated all those curves, so that I had only surfaces. But when you hide the edges, the edges that should look like edges become sort of fuzzy. Of course you want to hide all the edges of surfaces that should look continuous. One thing that I did in that regard was to make curves of all the edges that I want to be seen as edges then I gave them a different color. As I said, the model shown was just to look at. You asked about 'Joining' the surfaces of the cylinder model.
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