I'm sitting here thinking about your problem! I have the Horizon and am using the Acufeed on a quilt now. It works beautifully without any noises. Do you have the acufeed foot on correctly? You have pulled down the part from the back of the machine that fits under your acufeed foot? I have had thread break where it splits and bunches up in the needle hole on occasion-not sure why. I think it is more to do with the thread than the machine. I would try using the acufeed on a scrap piece of fabric that you sandwiched with batting and see if the same thing happens. I use similar needles and thread as you. You have the machine that will do the job!!