The rougher resolution wouldn't have anything to do with the toolpath right?
Nothing at all. It's strictly a tool to help your video card/processor work a little easier.

As for your facet problem, it has been some time since I took the surfacing class and my current company does not have the module (99% turning work here), but here are a few things you can try:

Turn on Flash CPR and right-click the render menu. There should be an option called "Analyze Cut Part" about halfway down. You can then select an option to show gouges or remaining material.

It's hard to guess at your geometry, but it sounds pretty curvaceous... have you tried a 2-curve flow and synced your points?

Again, I have not used the surfacing module in over a year, so I am throwing out suggestions based on my notes. Also, going forward from TXMan's question, if you have not physically cut anything yet, I would suggest a trial piece to see if the facets are real or perceived.