let me try to explain.
I begin with a poly cube with 6 sides that i convert to a sub-d cube.
Then i extrude the top face 3 times


So far so good.
Then i take the 4 side faces that develop and extrude them to pull out the depth of the head. What i get is 4 cylindrical protrusions.

To make the protrusions into one solid piece i delete the inbetween faces selected in the following picture

The result is as follows:


My question is simply does anyone have any idea how i can get rid of the curved lines that i have highlited in red in the above picture? I realize these are the lines that were previously
de-linetating the cylindrical protrusions but now they are a complete pain in the ass. I would like the lines to go vertically and horizontally straight around the figure. As it is shown above this provides weird effects in the figures finally geometry because it causes weird edges. Does anyone have any idea how i can get around this problem?
Any help at all is greatly appreciated...This is really pissing me off =)