The thread is brand new so that is not it, the eye of the needle is large enough I'm using 50 weight thread. The thing is that I've been using the same thread since I got my machine (the Q'nique BTW ) and this just started I've changed threads and it just got worse. This is why I posted the question, wondering what anyone else was using. Am thinking of ordering some Aurifil to see if it makes it better. Also did try the other trouble shooting suggestions.