Never mind, Basically the issue is/was that there was a
larger gap between the surfaces than the size of fillet I wanted to
apply. My thought was that the surface(s) should extend as needed
to fit to the fillet desired between the surface edges, not so, oh
well, something for SW to work on
, Other packages can do this I work with, so I just assumed the
wrong thing, thanks for all the help
Charles, your are right as noted above with this exception,
you can face fillet a set of surfaces only if the gap between the
surfaces is less than the radius of the intended fillet, if the gap
is larger you need to extend one or both of the surfaces. Just to
clarify, if the distance between two surface edges is two inches,
and the desired radius is 1/4", the surface edges do not extend
automatically to meet the needed fillet edges. Enhancement requests
have been placed, but more would be helpful.
http://forum.solidworks.com/forum/messageview.cfm?catid=20&threadid=3614&enterthread=y
*Edit: Although it can still be finicky at times. You mighthave to "extend surface" so they at least are closer thanthe radius of your fillet.
Matt Lombard has a response to this question on his Blog, whichincludes a link to a CADjunky video of it.
Having this benefit would be helpful. I will follow suit and headover to the enhancement request page.