Ok, here’s exactly how I am doing it in Illustrator CS2. I'll do this step by step so I am hoping someone can tell me a better way. I really don’t mean to thread-jack wildhock's original post, but I think it’s along the same lines...
Here is an actual file I just finished for cutting on vinyl. It took me about 5 hours to "fix" the original file so it was correct for plotting.
... as you can see the stroke path has been combined and duplicate sections removed and paths 'joined' so the plotter only cuts around the border.
So starting fresh, here’s just two letters that combine the majorit of my issue when they are on an outline multi-layer assembly.
then I am selected the layer and right clicking the selection and choosing "create outlines" to get the paths.
Then I duplicate the layer and add the thick stroke.
Select the stroke group and go to "Object | Path | Outline Stroke". Then I delete the original text letters...
Then in order to remove the center sections of the compound path, you have to select each layer and right click the image and choose "release compound path" (this is also in the ‘object | compound path’ menu)
Delete all the extra layers of path parts you don’t need. There always seems to be stray single anchor path layers left over too. At this point for ease of viewing I change the two inner cut outs of the "e" to white fill
The "k" is easier since it doesn’t need an inside cut out. For the next problem I have to move all the intersecting layers into one group.
HERES MY BIGGEST ISSUE: As you can see, the paths overlap. The plotter will cut these lines so they all have to be joined into just 1 path of the outer most line.
I changed the color of the e just so you can see the difference between the two layers.
First thing I did was select the pen tool, add new anchors on both the e and the k paths at their intersecting points.
Then pick up the 'path select' tool and select the path line that is overlapping on each and delete it till you just have the two open endpoints. I found it helps to lock the other layer so you can click and drag a box touching the line. Did the same for the k.
Then I join the end points. both layers unlocked, dragging a box into both end anchors... or if you have to get fancy, holding select - click end box, release select, click end box again to select only the end, then hold select and grab the end of the other path.
Right click, 'join path'. if you don’t have only those two end points, and they're both in the same group it just errors out and you want to throw your mouse. None the less, eventually you get one solid outline (which you have to keep adding letters to) and the inside cut outs.
Now i have two layers to send to the plotter... one for the grey background layer and only for the orange top layer.
This is a ridiculous process. doing "aplhenke" this way was stupid, what if i had to do a whole set of lettering for something... I’d just turn down requests for anything over 5 letters lol.
Help?