I used the "stroke" effect set to "outside" with 169px to get it nice and thick.
However, the effect does not produce completely smooth corners.
See here:
What is the best way to round font/text edges and get a perfect smooth result? I am open to any suggestions, it does not have to be the "stroke" method.
Edit: Ok not all suggestions:I do not want to use "Quick Mask Mode/Gaussian Blur" http://www.itechies.net/tutorials/psexample/index-pid-round-text.htm