Didja try a different bobbin? You might have a burr either on it or on the bobbin case (may have happened when the needle broke). I have heard burrs can be sanded out with a product found at hardware stores, but I can't remember the name of the product. Does anyone out there remember? I think it recently was in a "Threads" magazine article about home maintenance. Personally, I leave the repairs to the professionals, tho. You might email the company for suggestions as well.

Did you try tightening (increasing the top tension) the top thread. On any sewing machine, you will get loops on the bottom if the top tension is too loose and bobbin loops on the top if the top tension is too tight. Increase the top tension by 2 numbers to see what happens.

Other thought is are you using the correct type needle for the fabric you are sewing?

I've had this problem, and mine was a pretty bad burr on the throat plate right where the needle goes through. Go to the hardware store and see if they have any crocus (sp?) cloth. It's like a very fine sandpaper. If you close your eyes and run your fingers over your throat plate, you should be able to feel the burr, even if you can't really see it. It doesn't take much of a burr to catch the thread.

Another thing you might try is go through the thread path of your upper thread and make sure the thread is actually sitting in the take-up lever. Once in a great while mine will slip out, and it causes a big bird's nest underneath like you're describing. Good luck!

Laura, that's exactly what I was referring to. Crocus cloth. You're right, it is more likely a burr on the throat plate than on the bobbin case, but that CAN happen too. In case there are loose threads floating around inside, I suggest one of those little computer vacuum cleaners to suck them out. Never blow inside your machine (especially if it's computerized), as the moisture in your breathe can cause condensation and rust inside your machine.

Mary

Okay, I found it was the bobbin case. It has a tiny chunk out of it and several needle holes in it. (Its made of plastic). The thread was catching on the rough spots and not releasing to make a stitch.

I will be replacing the bobbin case and then I think it will sew fine again.

Yikes! bobbin case made out of plastic????