You may be having an "antialiasing" problem. Are the variations in the widths of your lines just 1 pixel?
I've written a set of routines which are substitutes for several of the original IDL plotting routines. You can download the set from the "code contribution library" under the plotting section:
http://www.ittvis.com/cod...product=IDL&catid=19
Unfortunately I don't have one for "polyfill", but perhaps you can create what you want with the "plots" command (or the antialiased version called "plotssmooth") using an explicit line thickness.