This message was posted by signman on AmayaUsers.com. PLEASE DO NOT REPLY VIA EMAIL. Instead, respond to the thread on the WEBSITE by clicking here: http://www.amayausers.com/boards/ultimatebb.php?/topic/2/537.html#000004 We had the same problem until our life saver service tech came up for routine warranty checkup. He spotted the problem immediately... the hat 'brim' was hitting on the back of the needle casing (I use the CCF hoops) and so I ordered the adaptor to hold the brim back. Everytime the hoop would move forward, that brim would hit and you could see it pull the face about 1/4" and...snap, another needle shot. With the CCF, most images can not be any larger than 2" high (we have older Big Red also, not the XT). And I use a very still 4" roll of backing-set sewout to go from bottom (brim) UP, and center 'out' for most lettering and designs. This keeps the face from puckering up like it would if you went from top down-and starting in the center first ties the face to the backing. When you hoop the hat, I think it was Aaron told me a year ago to bend the crim backwards first on the 'precurved' hats-then when you hoop it, firmly push the flat of your hand to squash the face right down while you tighten the clasp. I also 'steam' the faces on the 6 panel hats that have the extra binding sewn inside to cover that center seam. We use a handheld Oreck steamer-no covering-right on the center steam Unless you have bad water or use juice-steam won't discolor the hat. It does make it a little more pliable and easier to sew. Remember-a design that sews perfectly on a shirt will not work on a hat..you have to remove some density, play with the fills, etc. to get it right. I hate hats...takes too long to do them and make any money...but we do get orders too small to send out. =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list ===========================================================