Odd artifact on Double Porter Font

I'm creating some packaging design, much the same as I have in illustrator before.  In fact this is a rework of an older packaging file we've used before. I'm using a font called Double Porter 4.  However, there is an odd artifact on the letters "U" "D" and "O".  It only occurs when the font is larger than a 11pt.  We've been using this font for years and this has never happened before.  Here's what I've tried:

• converting the font to outlined and using various tool to try to remove it.  It isn't selectable,
• deleteing the font from my system and re-installing... no luck
• deleting illustrator preferences... also no luck
• deleting and re-installing illustrator... still no luck
• stepping back several versions... nope
• exporting the file, using another vector editing app.  (when I opened it in this app it was not showing the artifact so I exported it as an svg file, imported it back into illustrator and copied and pasted it into the file.  however the artifact returned as soon as I saved)

I've looked at the same font on several different applications such as Word, Keynote, Pages and nothing shows up here so I'm assuming it's not a system issue.

I'm honestly at a lose and open to suggestions.