un1corn wrote:If I create a fusion to try a chamfer all sort of weird things occur, I am sure that it is my lack of experience causing these problems.
I don't think it's possible to Chamfer your model as it is now. The CAD kernel can't deal with where your threads meet the cylinder.
Also, Fusion fails Check Geometry with BOPCheck enabled. This can be easily fixed by using the Placement property to rotate the cylinder a little bit about the Z Axis so that the seam of the cylinder doesn't line up with the seams of the Sweep. I rotated the cylinder 10 degrees, and then Fusion was valid.
But cutting threads works better for me than adding them, so I used a different approach (probably pretty close to what Mario linked to):
If you have any questions, post back...
OS: Ubuntu 14.04.4 LTS
Word size of OS: 32-bit
Word size of FreeCAD: 32-bit
Version: 0.16.6532 (Git)
Build type: None
Python version: 2.7.6
Qt version: 4.8.6
Coin version: 4.0.0a
OCC version: 6.8.0.oce-0.17