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Install a brand new needle that is compatible with the thread and fabric you are using.
Remove the top thread totally from the machine.
ALWAYS RAISE the presser foot and rethread the top thread from the beginning.
Confirm the thread path is correct.
Retest your machine.
Be sure that when you thread the top thread, ALWAYS RAISE the presser foot. This allows the thread to seat firmly in the tension disk. Sounds like what you are experiencing is called bird nesting or thread nesting.
That is called bird nesting or thread nesting and usually results from: mis-threading, thread not seated fully in the upper tension disk, or upper tension too loose. (Mis-threading may not be a user error--sometimes the thread will "jump" out of thread guide or the take-up lever.)
Remove the thread from the machine. ALWAYS RAISE the presser foot and rethread from the beginning. Verify the thread path is correct. Set the upper tension at the midway point between high & low number and retest your machine. The upper tension will probably need some tweaking for your particular machine, but the mid-point is a good place to start.
Not sure if this is the answer, but be sure to RAISE the presser foot when threading the upper thread. This helps seat the thread in the tension disk.
Bird nesting usually occurs because the thread is not in the tension disk or the thread path is incorrect. Frequently, a bird nest will occur when the thread jumps out of the takeup lever.
However, there could also be something wrong with the tension disk itself.
I have fixed it now the bobbin case didn't seem to stay seated during sewing or tangling i should say!. I decided to change the needle and from then on everything worked fine.
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