I'm thinking the paint bucket is not willing to consider the anti-aliased pixels along the edge of the stroke the same color as those under the point where you applied it.
This is probably a situation where you could be doing things a different way or in a different order to get better results.
Why not create a filled shape, then stroke it? I did that as an example and didn't see any discontinuity.
Another option might be to make a selection out of the path then painting it with your solid color, then stroke the path.
The reason is brushes in photoshop always have a little anti-alias with the
paint brush tool even at 100% hardness. If you were to use the pencil
tool instead to stroke the path then you probably won't see that.
If you don't need a brush for the path stroke, try turning the path into a shape
layer and then using a layer style to stroke the path.
With the workpath active go to Layer>New Fill Layer>Solid Color, then to
add a stroke double click on the color fill layer in the layers panel to the right
of where it says color fill and choose stroke from the layer styles dialog.
Added: Since Noel already said basically the same thing, this is just adding
to his good information
Message was edited by: MTSTUNER
Thankyou both for your answers,
Using the pencil tool works 100% for my needs and filling before stroking also works, however leaves me with another question which I think is as much photoshop as illustrator.
Ive seen video tutorials of people drawing in illustrator bringing their brushed stroked path over to photoshop and colouring it in using fills of block colour and not having the problems im talking about.
Many thanks for your answers
I've been trying to solve this issue as well. I use the brush to draw a anti-aliased line. Afterwards I use the paint bucket to fill up the area, but a small line stays visible (2 or 3px), even with the tolerance set to 255. But not always, some of the time the problem doesn't show.
I found that if I draw in a canvas with a white background, the problem doesn't show, but if I use a transparent background, the problem is there.
I outline a hand-drawed sketch, so I need to see the underlaying layer, which is why I used a transparent background. Since this causes the problem, I now use a layer with a white background, and the blending mode set to 'Multiply', so I still see my underlaying sketch!
Hope this helps some of you as well!