illustrator: pathfinder minus front, cut-out is crude, not precise enough

CS5.

Trying to cut out text from a shape behind it. I select the text, then Object > Expand…, then select it along with the rectangle shape behind it and do Pathfinder > Minus front. The cut-out shape comes looking wrong.

Before

After

In Pathfinder Options, I have the precision set to 0.001 pt (although it doesn’t seem to change anything), the other options don’t make a difference either. I’ve only had this problem with this particular rounded typeface. Any ideas how I can get it to cut directly along the outlined path?

Answer

The issue was being caused by the rounded corners effect applied to the shape being cut. Moral of the story: rounded corners must be done manually if you don’t want to alter the shape of the negative space within the shape as well.

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