Quick surface filleting tip
This is a question that came up in comp.cad.solidworks, and I thought I’d pass it along. A fillet can only be made between separate surface bodies when the Face Fillet option is used, and the fillet can be made without extending the surfaces. The fillet will automatically trim back and knit the bodies and the fillet into a single body. If the gap between the bodies is too large, use the Extend Surface or Untrim Surface features to glose the gap sufficiently. See this CADJunky video for the particulars. Use the Fullscreen option to see the details more clearly.