Is the stroke not aligned properly, or is Unite not working properly?
Open a new Illustrator document. Create an elipse that's 10" W x 10" H. Apply a 30 pt stroke to it, and align that stroke to the outside of the shape. Select Object > Path > Outline Stroke. Click the Pathfinder panel, and select Unite.
If you're experiencing the same issue that I am, then you'll find that there are stray points and paths inside of the newly-united object where either 1) the stroke wasn't aligned precisely to the outside of the shape, or 2) the Unite function didn't work properly.
Which is it? Is there a simple fix to eliminate these stray points and paths? It's easy enough on my circle example, but when dealing with something like text, it's very time consuming to go into each object and delete the stray points.
