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Intersecting vertices During extrusions

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I have been working on a very simple model based off one letter from Motext. I have started adding details to the model via extrusions of different faces and I keep running into issues on the edges of the model…they keep separating. (Yes I have the box checked for this not to happen) Upon further analyzes it seems the paths are overlapping creating what seems as separation…. At .35-1cm extrusion depths why am I seeing this issue on a relatively simple model?  I have fixed it; but down the road as this model becomes more complicated, I fear this could become an issue.


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