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I hope someone has some advice for this problem. I am making a t-shirt quilt and the blocks are pretty large (19 x 19) because the t-shirts were large and the designs on them, as well. I did stabilize them and now it is time to make my sandwiches (I'm using a cotton backing and I'm debating on flannel for the middle.

I did start sewing one sandwich, with the flannel middle but my machine (Baby Lock Melody) will not sew over the t-shirt decal. It bunches up the fabric underneath and I've had to tear it out.

Next I tried doing a block w/o the flannel in the middle - same thing. I can sew up till I get to the design on the t-shirt and then I get the bunching again.

Some t-shirts have the design over the entire shirt.

Any suggestions on how I can make my sandwiches or how to sew over these decals? I changed my needle, cleaned the race and am using a longer stitch length, but no luck.

Thanks!