When using outlines you have to design your character carefully.
Each joint should be a perfect circle so that the outlines do not get wonky when rotation is applied.
Here, the upper arm should be behind the upper torso with the outline on the upper torso just touching the outline of the upper arm.
76% of original size (was 662x19) - Click to enlarge
Then you end up with the parts outlined like this:
76% of original size (was 662x19) - Click to enlarge
With the arm behind the torso you can rotate the arm, and since the outline on the arm is continuous it will work correctly:
76% of original size (was 662x19) - Click to enlarge
Attention to the shape, rotation, and pivot points for each body part is critical to get the movement correct so that the outline stays correct.
Also the use of masking can be helpful.
Hope this helps,
Jeff
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