David, I haven't done hats, so I am certainly not an expert, but I have had excellent results using a metallic needle from Madeira. The eye is bigger than the regular embroidery needles. Maybe the polos, tees and sweats are more forgiving than the caps, so the needle could be the solution. Mary Mary Buckle Shuffletown Embroidery Charlotte, NC 704-398-1273 -----Original Message----- From: amayausers-bounce@xxxxxxxxxxxxx [mailto:amayausers-bounce@xxxxxxxxxxxxx] On Behalf Of dsklar@xxxxxxxxxxx Sent: Wednesday, May 24, 2006 11:26 AM To: amayausers@xxxxxxxxxxxxx Subject: [amayausers] Metallic Thread I recently had a job with 8 caps (unstructured), polos, tees, and sweats. All used the same logo. Parts of the logo were stitched using metallic thread. Everything went fine except for the hats. It took several hours to get the hats done. There was a thread break every few rows. It seemed to make no difference whether it was stitching the underlay (density irrelevent) or the actual fill. The polos, tees sweats sewed without problem using a 75/11BP. For the unstructured caps I used two layers of medium tearaway backing. I started with a 75/11 sharp went up to 80/12 sharp (don't have bigger), changed needles (to new ones and location on the machine), but could not make any difference. The problem area is not on or near a seam. I played with the material thickness as well. The cap was on a WACF. I have done plenty of caps. I have done some metallic before. But this is the first metallic on caps. Any thoughts on what the problem was? Thanks. David Sklar Ballyhoo! Arlington, VA =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list =========================================================== =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list ===========================================================