Well it's good to know I'm not approaching building my graphics in the wrong way, haha. I'm working in picas actually, I didn't think the type of units would make any difference.
I'm not quite sure I follow what you're suggesting (perhaps too much BBQ on the brain right now) but some points are on whole values and some aren't. I'm not sure how I could change those to whole values and maintain proper geometric proportions, though.
Some additional info:
1. Just saved PDF and EPS copies. Both show the hairlines in the following: QuickLook, Reader, Preview, when placed into Illustrator / InDesign / Photoshop, and when opened directly in Photoshop (with the exception of the EPS). Only the EPS opened directly with Photoshop was free of the hairlines.
2. When exporting to JPG and PNG, using the Type Optimized setting retains hairlines but they disappear if Art Optimized is chosen. So that's one little trick I just learned.
So there are ways that I can save them without hairlines, that's great. But once I distribute PDFs and EPS files for the client/third parties to place into publications for electronic distribution the hairlines will appear in those documents. I could ask them to place hi-res raster files instead but it doesn't give them the flexibility that vector graphics afford.
Is there a similar option to 'Art Optimized' I'm overlooking when exporting PDFs and EPS files? As a test, under EPS Options > Transparency I tried both the High Resolution and For Complex Art presets and it didn't make any difference.