connect but not over lap
As Monika said, screenshots help a lot. You didn't even tell us, what font you are referring to much less anything else.
Set the text.
Apply the Unite Pathfinder.
I agree with what Mr. JET posted. Also keep in mind that if you have your type stroked, after converting to outlines you should then Path > Outline Stroke before uniting. When done, then set the stroke for all to .5 pt or 1 pt. At least that's what we do for our router cutter.