Try using a top stitch needle. They have a larger hole for the thread to go through. I feel your pain, the first few years I fmq, I was using the same machine. Last year for my my BD I got a Babylock Journey with something over an 11' HARP, What a difference. I still make sure my quilts are supported so there is no drag. Good luck. Hope you can get a machine with a larger harp sooner than later.