I have re-threaded and checked for obstacles. I am still having thread breakage just under the foot, but only with 1 type of thread. I used another thread, different spool, same tension but no issues or thread breakage. It seems like the thread is stuck and breaks just at the foot. Is there a possibility my spool is too large? I was using a Essentials cotton thread with 1200 yards vs a standard spool of all purpose thread with 220 yards.
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Yes - your spool is too large. But only for the spool pin on your machine:) What's happening is the weight of your large spool is dragging down the machine feeding the thread smoothly through the tension discs and needle. Once thread meets fabric through the needle action the accumulated strain causes your thread to snap.
You can buy freestanding cone holders and they work a treat for feeding (and safely supporting the weight) of cones AND those super yardage sized spools on the market today. Most people don't think of cone holders as useful for regular sewing machines because these cone stands are marketed towards serger owners but a serger isn't the only place for a cone holder - I own two cone holders but I don't own a serger:)
The cone holder supports the weight, feeds the thread properly through upper thread paths down to the needle and fabric - you don't have to use cones, your short stout spool of thread will be supported and feed just as easily on the cone holder as the taller cones feed through.
Prym and Hemline make cone holders and unless you go for the ultra fancy weighted base with the table clamp, the prices are very reasonable, usually between $7-$15USD or £6-£25 here in the UK where I live now. Depending on what country you live in, this is usually a relatively inexpensive bit of sewing kit that once you have it you'll wonder why you didn't have at least one sooner:)
Great pointers, Sunnie! New2Sew, why not check Google for do-it-yourself cone holders?
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