Joe, like you I pay attention to the wheel at start up. My Alvah is so stiff to start I turn the treadle wheel!
On recommendation, I took apart the shuttle again. This time I closely checked the bobbin. Looked good. Put a couple of drops of SM oil on a swab and shoved it in. OMS!!! The black crud that was in the bottom was thick. It took a soak with oil for 10 minutes and a small screwdriver scratching about to get it cleaned out. Much better results now! Still rather noisy but the stitches are acceptable.
I am finding that the stitch length is off. Even at the longest throw of the feeddogs I get 12 stitches per inch. Right now I am hoping more oil time (soaking it in) will improve its function. Everything on the underside moves freely. Suggestions anyone?