Any font with variable widths should be attempted with the auto-density feature turned on. You didn't specify as to the size of the lettering (height) so I'm assuming your doing small lettering. If you are in fact running small lettering, a density of 4 may be too low. Also, if your doing small lettering, you might want to consider changing your underlay stitch length to something like 15 - 18 pts. If you say you ran fine before and now something's different, I would assume your bobbin case is clogged with lint and is reeking havoc on your thread tensions. I'd also lay off the spray adhesive as it might be getting into areas where it doesn't belong. Spray adhesive is for specialty type work and should not be used on a daily basis. Of course that all depends on what type of work you do on a daily basis. Give it a shot and let us know what happens. Ed Ed & Maralien Orantes E.M. Broidery 900 Terry Parkway, Ste. 200 New Orleans, La. 70056 504-EMBROID ery (504-362-7643) -----Original Message----- From: amayausers-bounce@xxxxxxxxxxxxx [mailto:amayausers-bounce@xxxxxxxxxxxxx]On Behalf Of Lee or Terri Hoover Sent: Tuesday, June 14, 2005 10:13 PM To: amayausers@xxxxxxxxxxxxx Subject: [amayausers] thread breaks - help Hi All, I thought I was getting better at understanding some of this embroidery stuff. However, I now believe I'm back to square one. I cannot seem to get a sew out on lettering of less than 2000 stitches (no less than 10 fraying thread breaks). The thread creates a lump/knot on top or below the material, frays and breaks. I've changed needles, rollers, threads, needle #, material thickness, bobbin, bobbin case, oiled and have not made it any better. What am I forgetting? Oh, and I sewed this 7 times last week without a problem (and attempted to sew it in the same way). Here's the details: Lydian .45 in Stitch length 20 pt Connections - closest pt Stitch type - satin Pull comp 120% Density 4 Short stitches off Primary underlay - center walk 30 pt. Tie in/tie off - only when necessary Speed 1100 spm Material thickness 3-6 tried all of these (last week used 5 successfully) Lettering "Got Sheep ????" Thread breaks are not in the same place. Sewing on Gildan 100% cotton t-shirt using polymesh backing "adhered" with Stick It spray adhesive. What can I do to remedy this? Thanks, Terri Hoover