Well...on going saga, but different twist... we checked the needle plate, check the hook and cleaned everything out. Here is what is happening now...I can run through the lettering without any thread breaks (or needle breaks) with backing only on a test sew out. Sews out beautifully. When I put a piece of the fabric on (100% nylon) and try to sew out the lettering I get thread breaks. I am using a 70/10 sharp titanium needle with regular cut away backing. Can anyone tell me what you use as far as needle and backing on nylon jackets? Thanks Barbara Avalon Embroidery