Static Mesh Distorted After Merging Spline Points

I am using a spline to generate a curved wall with a roof and stone foundation. I take a smaller static mesh section of the wall and add it to a spline. Then I use the spline to generate a larger wall with the length and curvature I want. Then I select “Merge Actors” to turn the spline wall into a static mesh. However, the static mesh comes out distorted; kind of like an ultra low quality LOD of the original. Sharp corners and rounded edges become uneven and misshapen. Its hard to describe. I check the LODs and tried converting the distorted mesh to nanite but, but I can’t seem to get the mesh wall back to quality of the original spline wall. How can I fix this? Or is there an alternative?

Hard to say on just this description.

Given what you need to do, I suggest you just go around the problem alltogether and generate proper geometry in a DCC instead of using (or trying to) the engine for it.

Simply put - it’s the right way to do things…

Does “DCC” mean digital content creation? Like maya?

Yes, maya, blender, houdini (you should really give that one a try, its very numbers friendly to where a wall on a spline is a joke to set up), max, etc.