James Kasson had the correct solution. Attached is his email and a picture of the correct transition. The bottom line is both sketches are rectangles with corner fillets. Not exact, but close enough for government work, however it is missing the folds in the round portion.
It will be good enough for the sheet metal guy to make it correctly. Typically these are made in two halves and joined together.
David Haigh
Phone: 925-424-3931
Fax: 925-423-7496
Lawrence Livermore National Lab
7000 East Ave, L-362
Livermore, CA 94550
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