""""""""""although I would avoid using the actual letters for the surface creation. """"""""""""""

Hi Steve,
Could you explain what you mean here? Here is the Times New Roman "I" from Michaels example, and i dont really see anything wrong with the surfaces created. This one was done with sweep. I also did one with loft that produced a surface with less control points in it... But it appears they both make a smooth usable solid.... ?????

Are you refering to just "fonts" in general as being poor geometry to start with?