Again, no expert here but when you work with scripts they do not connect together perfectly. If you enlarge Cats you'll see the connecting points and their overlap.
I suspect that it's this overlap that's causing your problem. I can suggest a work around but it may not be the best one.
1. delete the outline
2. convert Cats to curves and break apart, note that you will have to create the holes again in the a and the s later.
3. select all and weld
4. outline all
5. from copies of the a and s convert to curves and pick up the "holes in the a and s and outline them and put them in place.
There's probably a much easier way to do this but this should work for now.
Mike
Dist. of Lazer Cutting Grid
www.stl-laser.com
