The issue was the needle bar height, from a mark on the bar it was 1/8" off, my husband changed the height and it still bumps. My hubby also found the bar under the machine had pliers marks on it, deep ones, think someone was "timing" it??? My husband will hopefully have time to look at it again tonight.
I would have sent it back but really $100 for a machine that needs work, well, it will have to do.