Roland, I had troubles with a flex fit. I too was about to give up when Aaron suggested I try 2 layers of stiff cap backing. It worked! You might give it a try. My 2 cents. Dorothy Compton Bee Embroidered (916) 635-7467 Rancho Cordova, CA In a message dated 12/22/2006 7:01:37 AM Pacific Standard Time, signman@xxxxxxxxxxxxxxxxxxx writes: Good morning all! Herb, I gave up last nite in disgust, after 9 hours of beating on the Amaya... went over all the tips you gave me on the phone, and Rod sent me via email, and I think it was Russ (? sorry, I was tired when you called) gave me some more pointers that went along with everything else. This morning I managed to get the hat finished that was breaking every letter multiple times so I could get it off the machine. I think you hit it on the nail Herb...It must be the hats.... the problems are the FlexFit fully structured high brows....no one can I get them to sit down flat like you showed me. Got that hat off, hooped up a flex fit unstructured...and it went all the way through the design until the little black 'tires' on the trailer and broke a thread. But ALL THE WAY THROUGH THE LETTERING WITH NO STOP! Unfortunately about 25 hats left are the structured so I'm going to call the customer and tell him to come pick out different hats. Have to see if I can move a few thread points at that one spot and then I have about 12 of the unstructured and light structured ones I can finish. Was not a productive day yesterday! 13 hats for 9 hours work.... So thanks for the hints everyone...the fine tuning on the lettering and detail work made a big difference and working backwards through one problem after another narrowed it down to substrate...(hat) being the big culprit! =========================================================== 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 ===========================================================