Hi, I am trying to do a puff Block O for a school, and have had pretty good success getting it to look okay. But not great. Here's my question. When I compare this one to collegiate licensed hats I can't get my string to lay as smooth or flat or appear as nice. I don't think it's too dense, it's a 2.3 density for the puff. Would a smaller needle do the trick? Also smaller weight thread? Those are the only variations I haven't tried. I can try the needle tomorrow if I don't hear back. But I'd have to order the thread if someone thinks that's the ticket. Any help appreciated, thanks, Peter Strike Logo Stitch Indianaplis, IN 317-525-3242