I have always had trouble with linetypes scaling between model and paper. In paper type psltscale and change the value to 1 this should then help with the scaling of the linetype in paperspace. Best to press the F1 key and type PSLTSCALE in and get a better explaination.

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As per the overlapping, can't you just break the line either side. Hatching intricate areas. Best way is to draw a polyline around the object and then hit the hatch icon and choose select objects and pick the polyline. Hope that helps.