In the assembly above, I have the corner a solid model circled that is supposed to represent a fillet weld.

To date the only way I have found to simulate the welds is to actually model them as a part. The sharp corner that is circled is not only inaccurate, but also a stress concentrator. I would like to eliminate the corner and make it rounded. The problem is that the weld follows the cylindrical surface of the transparent part in the image. I cannot simply revolve the cross-section 90°. Using a Fillet feature doesn't work either as it shortens the height if the weld at the corner.

My question has two parts:

1) How would you simulate the weld? Would you model the weld as a part or is there a better way?

2) If I must model the weld, how can I round of that corner accurately.

Thanks for any advise you can give. Also, I cannot upload the assembly or any image showing more detail per company policy.