I have an issue creating a full round. I first created an Extrude UpTo Surface (white surfaces) from the green surface to the blue surface axial to the red cylindrical surface. The extrusion is rectangular with the top edge tangent to the red cylindrical surface. This worked as expected.
Then I attempted to create a full round, across the white side surfaces tangent to the blue surface. This failed. What seems to be the issue is the top transition, but I can't figure out why. When I change the extrude to a blind value extrusion, and make it end just short of the blue surface, I have no issue, but as soon as the value causes the end of the extrusion to coincide with the blue surface, the transition issue arises.
Has anyone experienced this before? Were you able to fix the transition issue?