I have Adobe Illustrator CS3 and i use a vinyl cutter with the software.
When creating layers i expand the path of the original text and place the expanded behind the text to create a new layer. However, when creating the new layer, the cut lines of the text bubble together, making it impossible to cut. I have been getting rid of these cut lines by hand forever, and it's just too time consuming. I want the second layer to be a solid outline, but its impossible with all the cut lines. There has to be a better way!
I'm not sure I exactly understand what you are describing.
You outline the text (Type/Create Outlines), and place the outlined text in a layer that is beneath the live text.
I'm not sure what you mean by 'bubble together'
Are you using strokes on your text? Perhaps you need to Object/Expand, before outlining - or after.
Your cutter may also require to save your AI file to an earlier version. Maybe try saving as an EPS.
Just a few thoughts.
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