Toon outline rendering issue

First off, I'm an animator, the drummer of the CGI world. (Sorry if there is an easy answer.)

That said, I've gotten a character I've modeled and did a quick texture job on. I want to render in a flat shaded style, and I've been learning about Maya's toon outline node, combined paint FX.
The profile line works great in the viewport (see this playblast.)


But the profile line breaks depending on the camera angle when rendered. (see this video.)


I've tried oversampling, converting to poly's and a few other tips I've read here. But nothing seems to fix it for this model. I've also applied the toon outline to sphere to test it, and it renders correctly. This would indicate a problem with the model, so I exported the mesh and shader, smoothed the geo and deleted all history on the guy. I also checked that he was at a proper world scale, (and not too small.) Nothing seemed to help, and I feel a little stumped.

Has anyone seen this type of flickering?

Thanks for saving my hair!

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