Roland, thanks for the great ideas. I especially like the noodle explanation! This is a big design-about 14,000 stitches inside a 14" hoop and mostly lettering. When you're talking about the background fill, do you mean that "magic box" that I've heard about? Awaiting your guidance, Obi Wan... Sandra A&E Custom Embroidery 936.588.1015 800.291.6953 We make your life more colorful...and your business more visible! ----- Original Message ----- From: "Roland R. Irish III" <signman@xxxxxxxxxxxxxxxxxxx> To: <amayausers@xxxxxxxxxxxxx> Sent: Monday, February 13, 2006 4:08 PM Subject: [amayausers] Re: messy letters on terry towels > Hi Sandra.... > you are doing pretty much all you can do... > my suggestions: > if at all possible, convince the customer that the terrycloth towels > is like trying to sew on a plate of noodles...some of them are just > going to escape and not much you can do about it! > > Okay, they laughed at you. > If possible, do a background fill-outline the entire area you are > going to sew on-in Design shop do a manual 'stitch' right up close > around the lettering, then convert to fill and do a very wide open > fill-set your fill more as an underlayment and do it in the same > color thread as the towel itself. Then sew your lettering on top of > that and most of it will disappear if you do it right. > > Or, if you have some to test on-keep increasing the density and make > the stitches shorter-get down to 3.6, 20 point stitch or so-with an > underlayment of 25 point stitch, centerline and 80 % letter width. > What you are trying to do is to tie down all those loose pile loops > of the towel and get a smooth surface for your stitching to land (and > stay) on top of. > Last christmas we did a couple 'golf towels' for one woman-only 2 of > them I think-and I actually ended up sewing the design twice-right on > top of itself-instead of wasting time rebuilding the design. It was > some clipart from the Dakota book and one word underneath-so instead > of spending a half hour redigitizing and testing, I just sewed it and > repeated. Came out great and she loved it! But for a quantity order- > that would way increase your stitch count. > > You might also double up on the solvy and see if that helps hold it > down. > good luck-all else fails, turn the towel over and sew on the back of it! > > Roland > >