Ken,
Ya like I know what you mean. You can increase your fillet size (say from .050 to .125) between two different surfaces that have been filleted. If you were to disconect the surfaces and then delete the fillets then you can use the fillet between two surfaces, blend or no blend. Because the two surfaces are closer than the fillet distance it will work. But it doesn't create a seamless fillet to all the a joining edges like it does with the fillet edges. This is because it doesn't have all the information to do a real clean job. It not it's fault. Just the way things work.
It will still machine the model, just doesn't look real pretty.
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