Last night I started working on my first FMQ project (quilting my OBW). I practiced first, and kinda got the hang of it. Tackled the quilt itself. I got about 2/3 of the way done with the middle (borders are a separate issue) and then my top thread started breaking. I'd rethread the machine being sure it was correct (pressure foot up, etc.), changed the needle. Same problem. Changed the tension. Same problem. Started with a new spool of thread, new bobbin. Same problem.

I'm using a Sulky rayon thread and a size 11 quilting needle.

Any idea what's going on and how to fix it?

My machine is Janome 6600.

Thanks for your help!

Try changing your needle.

I had a problem like that years ago on my Bernina. Could *not* figure out what was wrong, so finally put the project away. Years later the problem was gone. I think in my case there was a tiny thread caught somewhere in the upper tension or lower tension mechanism, and it eventually worked its way out.

My suggestion is to take the bobbin assembly out as far as possible and clean everything. Clean lint away from under the feed dogs too. You can also run some *unwaxed* dental floss around your upper tension discs in case there is a tiny piece of lint or thread caught in there. (Do this with the needle up.)

I'd try changing your needle size -- that's what I do and it usually works.

rethread the machine, and change your needle.

Since you say you changed the needle, it might actually be a thread problem. Even though it's new to you, a spool of thread may have been sitting somewhere for some time. Sometimes between the manufacturer and the consumer, something causes a weak spot on the spool, and the thread will break there every time. I had gone through about 2/3 of a large spool of Coats & Clark 100% cotton and it started breaking. After checking everything like you did, I just tossed the rest of that spool and starting using a new one. And problem solved! So try putting in a different spool of thread and testing on a scrap to see if it is the thread.

I also have a Janome I use for FMQ. I found that I had to sometimes play with the tension depending on the fabric sandwich. But the real breakthrough for me was making sure I had at least a size 14 needle in and I do not thread through the very last snap on the sewing machine....you know, the one at the very edge of your sewing machine near the needle....that made all the difference and I didn't see any problem with the quilting stitch.

I'd go with changing to the larger needle size - and if that doesn't help try the thread. I've been there too with FMQ - but found size 14 needle does the trick. Good luck!

UPDATE:

I cleaned the machine thoroughly and did change to a larger needle (it makes sense that the small hole was hard on the fragile thread). This seemed to help. Also changed to my other FMQ foot (one came with the machine and the other was an optional extra...ended up using the one that came with the machine).

In fact I was able to finish the FMQ part of the quilt (main section). Found that the fraying occurred to some degree even when I was straight stitching (walking foot) around the first border. So I guess it's possibly the thread and its fragility. But it's so pretty with the little sheen :-)

Thanks for your suggestions!

Great suggestions.