Use a better thread, use a topstitch needle which has a longer eye. Sad to say but not all needles are perfect. I can put a new one in and it acts up. Put in another one and no problem. I started out with coats and clark and didnt like the coverage. Ive switched to Robison Anton and Isacord. I get it from discountembroiderysupply.com. Good prices and no shipping. Great service. My absolute favorite is Magnifico by Superior. I have only bought a few because their cones are so big. Another thing, do you realize that the bobbin thread ideally needs to be a thinner thread than the top thread. #40 for the top and #60 for the bobbin. Reduces bulk. In fact I think Brother suggests something even thinner for the bobbin. As you probably have found out, this is a super expensive hobby!