Solidworks Smoothed or Shell Material Removal

3D Design Volume Model
1

Hello everyone,

So I'm brand new to the forum and I need help with my project. We have to make measurements on a part and transfer it to solidworks. Unfortunately, the inside of my room is not easy to access and so I have to make a lot of assumptions.
So here is what I want to do:
 

I have to make a connection between the left and right cylinders through the variable section between the two cylinders.
I don't know if it can be seen well on the images, but basically I have "precise" trajectories to follow and so it's not really possible for me to simply make a leave (in addition this function didn't work at the beginning because the bottom fillet, at the level of the connection between the two cylinders, is variable and solidworks did as it pleased).
So I wanted to do it by removing the material with smoothing. Ok, this smoothing works well at the level of the two guide curves that it follows well, starting from the inside of the hollow of the cylinder on the right and going towards the gray sketch visible on the photos (at the level of plane 23). Unfortunately, it makes holes with the outside :/
If anyone has an idea of how I could achieve this, I'm all for it.
Thanks in advance

 

PS: I've had SW labs before, unfortunately we had seen that the smoothed boss which is still less capricious for my taste^^

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The problem is not very visible on your attached images

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If I follow the logic of my reasoning

the junction of your 2 cylinders must be hollow since you are talking about the inside 

Your cylinder on the right finished via a domed bottom

So create this bomb bottom via a revolution and shell function

after doing 1 removal of material on each cylinder via projected sketches 

These removal of material will give 1 section of each side 

it's up to you via a 3D sketch to create the neutral fiber (the axis of your 2 material removals  )

of this neutral fiber make X profile sketch for the first 2 on either side via a shift as soon as the material is removed via convert the entities 

others ensure that the junction of each material removal profile is respected

Once done, all this goes through a surface smoothing via the axial guide curves option

thicken this surface inwards and create a volume

All that remains is to make the internal and external variable leaves that you can adjust via x adjustment points

well if I understood the problem correctly

@+

 

 

 

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Hello gt22,

I'm going to try what you suggested. I think I wanted to be too greedy and want to do too many steps in one go. 
I will try as soon as possible because at the moment I am very busy unfortunately. Thank you for your answer:)

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