Expanding strokes leads to a different result when exporting artwork
Illustrators’ exported image (JPG/PNG tested) is different with when you expand strokes and unit them then export.
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It seems like the tolerance of Pathfinder exceeds the one you get when expand stroke with variable widths. I suspect these lines go to zero at some point.
Hard to tell anything without having an actual file to test. Do you still have it? Can you reproduce it anew if you don’t have the original?