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NX 7.5 Fillet Weld

NX 7.5 Fillet Weld

NX 7.5 Fillet Weld

(OP)
Hello all,
I am working in 7.5 with a sheet metal assembly that needs to be welded. Each sheet metal part, as well as the welds, is a component withing a master assembly file. I emphasize that the welds are in their own file so when I create the fillet welds the weld file is the working part. "Fillet weld" works fine if the parts are an exact fit. If not then I get an error for the tiniest gap (.00015mm) and the weld fails. I tried loosening the tolerance but that had no effect. (Is there a customer default that works for the tolerance?)
Here's what I do. Fillet weld. I pick each surface accordingly (note: the selection bar allows "Entire Assembly"), I know there is a small gap so I want to pick an "Edge Set" to guide the fillet weld. Now though the selection bar only allows for "Within work part only" when "edge Set" is highlighted. The weld file is the working part not the entire assembly so I can't pick the edge and I have to create a bead.
We would like to take advantage of the fillet weld operator to use the auto PMI symbol. This is not available in the bead operator.
I can't change the assembly structure in any way and cannot put copies or broken link surfaces in the weld file. It contains only the welds. GM TeamCenter gets fussy with broken links.
Where can I change the selection bar default to " Entire Assembly" when in the working weld file so I can pick the edge set?

If anyone has a better way to create these welds I'd love to hear it. The PMI symbols are eventually shown in a 2D drawing so we are trying to automate as much as possible. There are few tutotials on using the weld operators in NX.

Thanks in advancebigglasses

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