Thanks everyone for the suggestions! I was up til 3am determined to find out what the problem was! I had tried various size needles.. Went back to the 90/ ballpoint seemed to work the best but still dreaded skipped stitches!! GRRR I finally turned the tension to 5 which was never used that high before, figured my thread would break but no, and it worked pretty good! Haven't been back to tackle it yet today, hoping I can finish it! I don't have any quilt shops or repair anywhere near me unfortunately or I would of taken it weeks ago! Ugh