Im pretty sure those problems were caused by the regional geofabrik extracts who cuts the regions exactly at the borders, resulting in broken multipolygons.
The geofabrik extract of whole europe will avoid those problems. There are two ways to split a small section of the europe extract:

  1. with osmosis
  2. with a predefined area.list and the mkgmap splitter, but the problem is to calculate the borders of that region in garmin units. See also here: http://www.cferrero.net/maps/splitter_advanced.html