Thank you all for your suggestions. I have tried many types of thread; cotton, poly & a blend, all with the same results. I went out & purchased different needles & sizes. So far the universals cause the same problem as well as jeans and topstitch 90/14. The strange thing is on all my quilt sandwiches come out fine. Today I am trying to wash the quilt then try to FMQ to see if my spray baste/fleece combo is the culprit. I'll update hopefully when I've been successful!