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Not sure I can help. Suggest perhaps loosening the upper tension a tad so the upper thread will be pulled more toward the underside of the fabric. Have you tried a different needle? Perhaps a microtex, top stitch, or embroidery needle will make a difference since the sharp point will better penetrate the quilt sandwich. Also, sometimes the thread will be the source.
Sounds like the upper tension needs to be tightened, or the bobbin thread needs to be loosened. At any rate, the tension is correct when the two threads meet in the middle of the fabric for general sewing.
For free motion quilting, the tension should be adjusted so that the bobbin thread does not show on the top of the fabric, however, it should not lay in a straight line like it sounds like it may appear currently. What you are currently producing is a gathering stitch where the bobbin thread can be easily pulled.
Try tightening your bobbin tension a little, and then readjust your top tension again for consistant tension. Also if your not running the machine fast enough while your moving the fabric, you might have you bobbin thread looking like a taught thread on the bottom. Make sure you use a small needle, like a #11 or a #10. The smaller the hole the needle makes, the less of the thread you will see on the opposite side. Especially if you are using contrasting colors.
Make sure your are lowering the pressure foot first before you start sewing. With the free motion foot, you still have to lower the pressure foot, this allows tension to be put on the top thread and allows the foot to work properly (when the needle goes down so should the foot and when the needle comes up it should lift the foot up.)
Also make sure your tensions are in a middle setting and that you are threading the machine with the pressure foot up.
The way to insure you will not get your problem is with the foot up, you should be able to pull the thread easily right before the eye of the needle and when you put the foot down you should then feel a fair bit of tension on the top thread.
this is a known issue with the pfaff.....i have just bought the machine and it has thread uptake issues...thread tension issues and it comes unthreaded by itself often...leaving globs of thread on the bottom stuck in the feed dogs and under the throat plate.....then the stitches are not properly balanced because the tension gets too loose on the bobbin thread....very disappointed to find out it is a known issue with all the viking husqvarna made machines...which are pfaff, janome and viking.....sux.
It sounds like one of your clearances in the machine is off. When a machine skips stitches like yours is doing, it does so because the hook responsible for "catching" the thread from the needle is not close enough to the needle so it misses the loop of thread from the needle. If your machine was having a timing problem it wouldn't sew well on any fabric. A clearance problem shows up on certain fabrics at certain times. A few things you could do to try to compensate it would be to use a slightly larger needle and turn your top tension dial down to a lower setting. Move the machine a little slower on the frame or increase the speed of the machine. Either way a trip to your technician will be needed. Make sure you tell him to check the needle to hook clearance.
I need more info.
>Where is your presser fooot pressure set(1-9) it should be around 4?
>How fast are you free motioning (faster is better? from 1-10 10 being full speed.
>Is your bobbin threaded correctly (I need to cover the basics.)?
>Never never use a needle smaller than a 90/14 for free motion (I know everyone's an expert...but trust me)
After all this, it's OK to tighten your tension up on top a little when free motioning and getting eyelashes/spider webs on bottom. around 6 should do it though.