Have a look at the Brother 900D...I think it is a 950D model now. It has embroidery, and is a great peicing machine for $1000. I love it! I have had mine for 2 years and never a problem. It is amazing. I send it in to get it cleaned once a year, that's it.
Do you oil the bobbin case in the brother you have now? I bet that would make a world of difference in the stitching inconsistancies, if you don't. Try it. I oil mine every couple of days.