Originally Posted by
rryder
The first thing I would do is switch to a 100/16 top stitch needle to see if that helps.
Agree 100%.
I also would like to point out that the reason why so many people recommend top stitch needles is because the eye of the needle is larger, and the scarf is longer. As you can imagine, sewing (especially at high longarm quilting speeds) puts a LOT of friction on the thread. The scarf is an indentation in the needle that runs down the length of the needle. This gives the thread a protected place to lay as it moves in and out of the fabric.