I have a model that has issue's with a filtet from one config to the next. I am building a cored passage housing. The way we do it is we design the inner and then the outer around the inner. We then subtract the inner from the outer. That is the casting configuration. After the subtraction, we do our final machining. Everything should roll together as if it were one configuration but my machined configuration is happy but if I change to my casting config (using the config manager tab) a couple fillets have errors. Just simply rolling back before the combine (subtraction) in the machined config everyone is happy. Why do things fail by just using the config manager tab?
When dealing with castings that are later machined it is often much easier to actually have two part files. The first file is the casting and the second is the machined version, but it has the cast part inserted. (Open a new blank part then go to Insert -> Part and select the casting part file. Then you can cut on it all you want to make the machined part.)
The absolute beauty of this method is the parts are easily kept distinctive, yet related, If you make a change in the casting it shows up in the machining, but if you make a change in the machining the casting is unaffected. That is they way things would work when you have the physical parts.
Yes, this can be done with configurations and I am a big fan of configurations, but for this situation the Insert->Part is much superior. With configurations it is so easy to unintentionally change a dimension for more than one config or conversely, to change a dim on only one when you wanted it on all. If you really must do this with configurations then I suggest you use a Design Table because at a glance you can see what is different between configs. It also helps immensely to name your features and name the important dimensions if you are going to do this.