This message was posted by Rod or Sharon 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/2/955.html#000003 Both posts are good advice.....Tina's question is very important. Is the whole design and lettering sewing from bottom up and center out? The cap needs to hooped as tight as you can get it and lay as flat as possible on the sewing arm while sewing. In a case such as this...the presser foot is being forced to ride the steep incline of the cap just above the bill and is sliding down this incline and wedging itself against the back side of the needle which starts the breaking process. Check the clearance of the presser foot to the needle and make sure there is clearance..aprox 1/8 to around 3/16 inches is sufficient. If it is bent, you can use a flat blade screwdriver to gently shove the presser foot straight back to bend it to get this clearance..... You may need to raise the presser foot another notch or two....what speed are you trying to sew these caps at?? Rod Springer Amaya Tech & Trainer =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list ===========================================================