I don't have 2011 loaded, so I can't look at your part, but just because two faces are tangent doesn't mean that there won't be an edge between them. Make a sketch with two straight lines joined by a fillet. Extrude it. You get three faces and two edges joining them.
I suggest using trying
1. Tools>Deviation Analysis (Shows how far out of tangency the surfaces at an edge are)
2. View>Display>Zebra Stripes. (Displays the part as a mirror in a room painted with stripes)
3. Tools>Options>System Options>Display/Selection>Par/Assembly tangent edge display>As phantom (shows tangent edges as dashed lines)
I hope this helps.
Message was edited by: Robert Stupplebeen Added Image
To start with, you're not using any end conditions, like normal to profile. That seems to be because there is a problem with some sketches, where a dir2 sketch isn't perpendicular to dir1, so SW won't assign things the way you want.
Why are you using a combination of splines and arcs? Why not just splines? Sketch 5 and 6 should just be a single spline, as well as 4, 8 and 15. I would get rid of 15. See how it sits at an angle to the "fillet"? If you really intend a fillet, this part should be done differently, so that the fillet works more like a fillet, not trying to make a fillet from angled sections.
And then finally, the degeneracy at the center of the outer faces won't help you make anything smooth.
Working in this way requires an entirely different way of looking at modeling. It's not easy, and SolidWorks isn't really built for this kind of stuff, but you can often make it happen once you learn enough tricks.
This helped a lot Matt.
I was told not to use splines with more than to control points. So, my sketches are a bit complicated. I did try a few with one spline with a few more control points. It looks pretty good now. I just need to watch my inflections.
Getting rid of the extra sketches made life easier too.
The one hard and fast rule for splines is that there are no hard and fast rules for splines.I like to use two point splines wherever I can, but there are many times when it is much better to use one three or four point spline instead of two or more two point splines.