Need help - Merging objects with same fill color causes seams

[Cargrill]

Hello - I'm new to this forum - I was hoping someone could give me some help with an issue I keep having in Illustrator CS5. I have done many searches for help with this, but I could not find the answer. Sorry if it's been dealt with and I could not find it.

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I'm able to use Pathfinder>Merge to join objects with the same fill color with no problem - but for some reason I often run into issues when my object was created from Expanded text or from an Effect.

As in this case:

I created this image using text with an Outline and the 3D Effect:
Attachment 100662

I Expanded the image's appearance and then Pathfinder>Merge - I want all the deep purple areas to be joined as one object, but you can see the deep purple outline won't join with the other shapes:


Here's a closer shot, with the objects unselected so you can see the faint outline where the shapes won't join:


Even if I try to get rid of the seam by creating a new object (same fill color) on top, and then Merge that, it just creates another outline. See, here I've created a rectangle on top of the seam and Merged, but the rectangle is still visible:


What is the best way for me to flatten this graphic so it doesn't have these seams?

Thanks in advance for any help!

[onedayteam]

Hi, I'm new here. Haven't had this problem before. But flattening it may solve the problem. I hope that someone will response to you soon because it's my first time to see this problem, too.

[mwenz]

Try expanding the art before using the pathfinder operations.

[Cargrill]

Hey onedayteam - I'm using the Pathfinder to Merge the objects, I'm not sure what method you use to flatten objects, but if you have another method please let me know!

Hey mwenz - I did Expand the artwork first - next I Merged. I did try to explain that - sorry if my explanation wasn't clear.

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I'm a long time Illustrator user, I just can't figure out why these objects that use to be outlines are being treated differently than any other shape. I finally had to select each section and manually connect them all with the Shape Builder Tool, which seems like such a waste of time.

If anyone knows why the outline isn't Merging - or has any tips for me to try - PLEASE let me know!

[Albacore]

Is it not the stacking order that is causing the problem? I am away from my computers at the moment but when I get back to them I will go through the process and get back to you. This evening UK time.