[/quote] I just hooped the iron on stabilizer and floated the easy stitch. i think that I need to invest in some different stabilizer.[/quote]
I find that two layers of regular pellon tear away stabilizer work well for dense designs. I only use the iron on if it's on a stretchy or delicate fabric.
I attended a seminar given by Cactus Punch designs years ago. They will tell you when they do custom work they digitize differently for knits than for wovens or hats. If the 'under layer' of stitches is not laid down well or if it's not present at all, your sitches will pull in and your outline will have gap-osis.
So sometimes it is you not doing things right but sometimes it's the digitizer.