Hairline in Name only

Hi,
I need to make a stroke less then one point. My laser cutter will only cut vector when the line weight is less then one.
I have used: Select>Object>Not aligned to Pixel Grid,
Make an outline and copied the style and pasted it,
and in the PDF turned off enhance thin lines.
All the lines read as .25, but on the screen some still look thicker. (See attached)
The ones that look thicker are treated like a 1pt line.
Meaning the are cut twice, once on each side of the line vs. along the line.
I have no idea why some are thicker and others are thinner even though illustrator call all the lines .25 pt.
They are mostly made with shape maker tool.
Running CS6 on Mac OSX 10.9.5
thanks

DirecTv is satellite based.
Did they install a Sattelite Dish and boxes?  Note that in an apartment buidling a shared dish may have been set with a distribution hardware to all apartments.

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