Your post made me laugh with the funny bone remark. :) I'm glad you found and posted a solution to your own problem. Bravo!
Happy sewing.
SOURCE: Babylock Ellure thread issues
I have the same machine and love it. Sometimes if the thread is old that will happen to me. And also I spray the thread with static guard before i thread the machine in dry cold weather. Since you said you are an embroiderer I assume you are using the same weight thread top and bottom. The other thing that causes that on my machine is if there is a nick on the spool of thread I am using and the thread catches just a little as it comes off the spool. I use a fine nail file and smooth off the edge where the little v is to reattach the thread when you are finish using it. I never use them. You do sew a little and cut off the tail off the top thread before you let it go through the rest of design. I hope you have found the solution but I learned these tricks while having the same problem as you.
SOURCE: Needle thread looping underneath, threads not interlocking at all
If the machine is now threaded, lift the presser foot.
Now, pull about 10" of thread through the needle.
The next time you thread the machine, lift the presser foot first.
When the presser foot is up, the tension control opens and allows the thread to "seat" into the control, then when the foot is down the control closes to the indicated setting.
When threading the machine with the foot is down, thread does not enter the tension control and when you start to sew, there is no tension on the thread.
No tension = loosey, goosey, loopy stitches underneath.
Because the lack of tension on the top thread, the bobbin thread cannot lock a proper stitch.
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I may have found the problem. There is a piece of plastic with a rectangular **** at the top of # 4 on the needles threading track. Tonite I looked through this hole with a small flashlight and found thread all wrapped around whatever is behind the thread 'pickup' lever. It took a pair of tweezers and a good hour to clear all of this out but the machine began to sew normally after I re-threaded it. It was like trying to remove the 'funny bone' in the game Operation. The difficulty which I encounteed in removing the tangled thread through that small hole appears to be a Baby Lock design flaw. I have owned many machines and never encountered a thing like this.
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