
You can see the bad stitching on the back of this quilt. When you use a bed sheet you are looking for trouble.
This is from Kathy Barlow of Kathy Quilts.
I just completed quilt #4102. And I have to share that it was the worst quilting experience that I can remember having. Here’s how it all went down.
It was my birthday last week, and I wanted to just leave the troubles of the world behind me and do something that I wanted to do for myself. Of course it was sewing something! I’d had my eye on an instragram post I saw a couple of months ago, of a quilt with a teal or turquoise background and plain black and white trees. I loved the look. Last year, I made a scrappy tree quilt for our bed at our cabin, and it was so fun making all those scrappy pieced trees. I decided to use one of the tree patterns and try to duplicate the quilt (after I’d spent hours trying to find the actual quilt pattern to no avail.) I knew I had enough low volume white and black fabrics but I needed a background fabric. I found some online on Etsy, but it couldn’t be delivered for over a week. I went to my stash. Yes, I was willing to cut into any of my precious fabrics if I could find enough of a similar color. There in my cupboard of solid fabrics, at the very bottom, was a turquoise fabric! And it looked like a good size, so I pulled it out. Yay! It was a good amount. Unfortunately it was a bed sheet!
I know the controversy, and I spread it around myself. NEVER use a sheet in your quilting! Sheets are so tightly woven (like 600-1000 thread count per inch as compared to quilting fabric of approximately 70 threads per square inch. I tell all my clients – be daring if you want and give it a try, but if it fails, know that you were taught differently. I have cheated this fact a couple of times by purchasing a micro fiber sheet for a quilt back, and that’s always worked fine. Maybe because of the softness of the fabric or maybe because of the cheapness. I was taught that if you really really needed to use a sheet, purchase the cheapest loosest count that you could find. Let me explain why in terms we might be able to understand. As the needle goes through the fabric, it has to pick up the bobbin thread at just the right time to create an entire stitch before it can move to the next stitch. If there is something preventing the needle from getting through the fabric at the correct time, this full stitch can’t be completed. What might make the needle slow down? Here’s a couple of reasons. Heat and bond! If the fabric is too stiff and solid, the needle has to work harder to penetrate that fabric. Sizing of fabric. Same reason. Stabilizer behind the fabric. Same thing – needle has to work too hard. High thread count! Same thing, if the fabric is sooooo tightly woven, that needle can’t find a good place to pierce the fabric and it takes just a split second and it’s missed the window of completing the stitch. Or the hook catches that top thread at the wrong time, and slightly cuts into the top thread, eventually shredding the thread. So my problem was the high thread count. I never imagined that it would be such a huge problem for myself. Anyway, back to my project.
I felt the fabric. Poly cotton blend. Quite thick, sturdy fabric. I loved the color. I was anxious to make ANYTHING and it was all in front of me. So I decided to bite the bullet and give it a try. My quilt blocks pieced up wonderfully. I singed one piece of fabric, so I knew it was a poly blend and I turned the heat down on the iron. It all worked out. I even had enough left to do most of quilt back besides. It was all ready, and I was caught up on client quilts, so I loaded it onto my Grace Continuum quilting frame and got started. Most of the time, when I use the Continuum frame, it’s because I want to run QCT6 Pro automation. I’ll usually get my Q’nique 21 Pro going with an automated design, then head over to custom quilt on my Gammill Classic—letting me work on two quilts at once.
The first row of the quilt, I kept breaking threads. Like the thread shredded 10-11 times. So I changed the needle. I decided to use a size 18 needle instead of my normal size 16. It didn’t seem to make a difference. As the quilting row returned from right to left, the breakage was even worse. I changed the needle again. I turned the needle slightly to the left. I dropped the needle slightly (these are hacks to use when your machine needs to be retimed but you just want to get through the quilt before you deal with it.) Nope, nothing worked. I finished the first row of my panto design and gave up and went to bed.
Two days later, I knew I needed to deal with the problem. I had a dream that if I’d soften the fabric some, it might be easier for the needle to go through. So I find a place to plug in my iron next to my quilt and spray the quilt with water and also use the steam from the iron to soften the fabric. I still had thread breakage. Next I decided to turn down the speed on the quilter, so I put it on the slowest stitching speed possible, I usually quilt with it on the highest speed setting. Nope, no improvement. I changed the needle AGAIN! All I could hear was that horrible popping sound as the needle tried going through that sheet (if you remember, my quilt back is ALSO THE SAME SHEET! So I’m dealing with a double whammy here.) I finally get through the 2nd row of my quilt (I have 7 rows total – I’m making progress.) I’m about ready to take the quilt off and put it with my UFO projects. Then I wondered about my thread! I’m using a good 40 weight quilting thread, (Perma core Polyester thread by A&E). Have I ever used this thread before? Is it my problem, maybe a faulty thread? It seems like a huge new cone. I change the thread. I find something that doesn’t quite match, but if I can finish the quilt, I’m willing to deal with it. No change whatsoever! Thread break after break. Within 5″ of the quilt from the edge, I’ve had to repair the design over 5 times at this point. I’ve started pulling my hair out by now.
One more fix that I can think of – change the needle again. I think this is the 4th time. I see some size 14 needles on my table that I never use unless I’m working on a Batik quilt. Let me explain about Batik fabric. It’s colored and dyed by using wax and dye so the fabrics take on that mottled coloring in spots, and leaving designs in other spots (for example, a light colored whale shape on the fabric, surrounded with blue mottled colors, making the whale stand out.) Because of the waxy content (and I’m sure these fabrics have been treated to wash out all the bad stuff), the fabric is still stiff. So if I’m quilting a Batik quilt, and I make a mistake and have to unpick, those holes never go away. It’s very blatent where I’ve made the mistake. I can try to use a toothbrush to smooth out the holes from the mistake, but they’re still always there. So I always change to the smallest needle possible when I’m quilting on Batiks so the holes are smaller where I make mistakes. Hey, my fabric (the sheet) does feel and sound like I’m quilting on a Batik (those popping sounds of the needle trying to go through fabric don’t always mean that a needle has a burr on it – it’s just hard for the needle to go through the fabric and you hear every stitch as it tries to pop through those stiff fabrics.) Last resort – I try the size 14 needle (Groz-Beckert Machine Needles). Well, I made it through 10 inches. Then 20. I make it through the entire 60 inch width of the quilt without thread breaking!!!!! My MIRACLE! I still had maybe 3 more thread breaks, but that was the entire 5 more rows of the quilt. I cried with thankfulness.

The quilt looks great after all of that pain and trouble but I still love it!
Here’s the recap. I was having a problem with one quilt. The previous quilt was fine. My initial sew-off piece showed no problems with tension or thread issues. The Q’nique 21 Pro longarm machine wasn’t broken. I knew it had to do with the quilt. I tried ALL of these things in order to find my fix:
1. Rethread the machine
2. Change the needle (in case it has a burr)
3. Change the needle (I went up in size because of the stiffness of the quilt.)
4. Change the tension (I went WAY loose in the top tension, hoping it would help stop the thread shredding.)
5. Clean the bobbin area
6. Oil the bobbin area again
7. Steam the fabric
8. Slow the speed down (this was actually quite helpful, although I still had thread breaking.)
9. Lower the needle slightly
10. Turn the needle slightly so it wasn’t exactly straight. (I never remember which side I’m supposed to turn it to, but I learned this trick so I try it both ways. One day I’ll write the correct way down so I remember.)
11. Wet and steam the quilt again. I kept the iron right by me and steamed the heck out of the area about 5″ to the right of the needle as it was stitching. Over and over.
12. Change the needle AGAIN – this time I went to the smallest needle size I had, size 14.
I’m positive I tried more tricks of the trade I’ve learned over the years (including crying a lot), and I’m glad I could remember several of them. Keep a quilting journal and keep track of ideas that have helped you as you’ve progressed in your quilting. You are welcome to share those tricks with us and we can all learn from others mistakes and fixes. What works on one quilt probable won’t work on the next as all quilts are different. But just having some options to quitting are so helpful. I didn’t give up here. I was so THANKFUL that this was my very own quilt and not a client’s quilt. And I knew why I was having those issues, and will I ever use a sheet again? NEVER! I’ve learned the lesson personally that I’ve taught others for years. Yes, quilt #4102 is completed and in the wash? Why am I washing it now? I’m going to show pictures of the horrible stitching on the quilt back, and I’m hoping they will sink into the quilt slightly so they won’t be so noticeable.
Happy quilting! I hope you all have a much better experience today than I have had. The next one will be so much better!
Love to you all!
Kathy








