Can't refine face mesh enough
 

I am attempting to model an aircraft probe that is a rather complex shape. I have an image below:

http://i39.tinypic.com/ftd4le.jpg


I have manipulated the face meshes to get worst element skewness to around 0.7, but due to the sharp tips (below), I can't improve beyond that. This is with the tips being meshed on a 0.25 spacing. I have a boundary layer attached to the faces of the entire probe, which starts at .5 and grows at 1.4 for 8 layers. When I attempt to volume mesh this (subtracted from a cube), using T-grid, it always fails, telling me to check skewness in areas of small gaps. No amount of refinement seems to get it to work. The only way I have successfully meshed it was when I used stairstep. However that ignores the boundary layer and produces a highly skewed volume mesh. Any tips or tricks on how to approach this would be greatly appreciated.

http://i42.tinypic.com/2pynfa0.jpg

Merge the 2 faces in front of your geometry, it will delete the diagonal edge which generates the small angle (and produces high skewness).
Do the same at the adjacent side (right side on the picture) with the other diagonal edge.
;)

awesome, thanks.

Quick question. Could I merge the other two flat faces with the front one too without losing the shape of the tip?

Gambit won't allow you to do that, because the edge is needed to describe the shape.
What should be the aim for this? if the diagonals are gone, you are in the case of 90° corner (ideal)
But you can try (save before)
;)