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I have a brand new machine (sit down)and I can't get the tension adjusted. The only one who has tension around here is ME. I have tried the tips found on an earlier tension discussion without success. Even with the top tension tightened all the way down and the bobbin adjusted as suggested, the bobbin thread is still not being pulled up into the sandwich. Right now I just feel that I want my money back.
Have you tried tightening the bobbin tension? I do not have the sit down machine, but we were told that when there is a tension problem start with the bobbin first, then adjust the top as necessary. If you are holding the bobbin case with the bobbin up in the palm of your hand, the bobbin should just lift up on the edge or just off the palm when you lift up on the thread. YOu might need to tighten the tension screw on the bobbin case.

Keep us posted
Do you have the needle in correctly? The long slit on the needle goes to the front. Also, are you using the correct needle? The needles that should be used are 135X5 needles.

Do you have the bobbin unwinding correctly? When unwinding it should be rotating clockwise. I, personally, like my bobbin tension a bit tighter than what they show on the video.

What thread do you have in the bobbin and top?

If you do have the needle in correctly you may want to turn it JUST A HAIR to the right.

Keep us posted on your progress.
I have been having a lot of tension issues with my Fusion also. It seems like, regardless of thread, the tension varies as I sew. I check the bobbin tension before beginning, then adjust the upper tension to my satisfaction on fabric scraps. Sometimes I get well into the quilt before I notice that the tension is varying. Since it fluctuates from loose to tight, I am cautious about making further adjustments. The problem doesn't seem to be related to direction of movement and I've tried a variety of needles and threads. HQ and my local dealer have helped me double check my procedures with no improvements, so any suggestions will be greatly appreciated.
I have an HQ 16. I tried a thinner thread and could not get the tension adjusted, then the whole tension knob fell out - I put it back it but it won't work. My rep is off this weekend, no one answers at the HG site and I have a quilt due for a silent auction - to be turned in Monday when I go to work (auction is on Wed.) I have given up and guess I will be keeping this quilt for myself.

I have quilted about a dozen quilts so far and never had any tension problems until now. I wonder if this is related to the shaking that happens when I quilt - after about 1/2 hrs., the whole thing vibrates. I talked to the rep about it, she had not heard of that and was going to call HQ.

Anyone have suggestions on how to make the tension knob stay in and work?
Assembly of the upper tension knob isn't my problem and I would be happy to assist getting yours back together if you don't have any other resource this weekend. You need to get the parts back in the right order and facing the right direction.
First are the two tension disks with the beveled side facing each other, next is the silver spring washer with the concave side that fits the spring facing out. Third is the spring with the wide end facing in, fitted into the silver washer. Fourth is the black spring retaining washer and finally the knob. The assembly shouldn't vibrate loose when you have several knob turns of tension. HQ suggested that I begin my tension setting by completely tightening the tension knob, then opening up about 6 full turns.
I have identified my tension problem as a variation when direction changes from left to right. A lot of my problem was minimized by HQ's suggeston to adjust the spring on the inside of the bobbin case so that the bobbin prodrudes slightly beyond the case. This keeps a little "anti-spin" tension on the bobbin by holding it gently against the back side of the bobbin chamber.
I'm also working at changing guides so that the thread is more directly aligned along the groove in the front of the needle. The guide hole just above the needle allows the thread to pull to the right side instead of following the groove. Things are working better, but still not perfectly.
I have looked at the knob again - the problem is the whole knob pulled out and will not stay in - everything is intact. I have tried pushing the knob in and tighted the screw but it doesn't catch or tighted unless I hold the knob in with one hand and tighten it with the other and it still won't stay. As soon as I try to take a stitch it pops out and I get a messs of thread on the backside.
The entire tension assembly will come out as a unit. There is a small set screw just underneath the hole for the assembly. You should be able to slip the tension mechanism back in and tighten the set screw with an allen wrench. Make sure the set screw hasn't fallen out completely and that you are tightening it only after the assembly is properly seated.
I tried getting to that screw and did not have anything small enough. The local rep came out, tightened the screw, still would not stay in. She called Handi-Quilter and there is another screw - you have to take the whole assembly out - the little screw at the back of the assembly was loose. That was tightened, the assembly put back in, and the other little screw was tightened. now it works and I know how to fix it if it happens again. They do not know why the inside screw was so loose though.
Glad you got things worked out. My tension problem is back to being unresolved. Increasing the spring tension inside the bobbin case caused too much bobbin drag and the need for too much top tension, so I reset it. I can't understand why the tension would change with side direction of machine movement. I added two new thread guides to my machine thread path using fishing pole line guides, as demonstrated in a Gammill you-tube video. I think this will be of overall benefit, but still not correcting my present problem.
I have a problem with my tension, also. When I am quilting the top thread pulls the bottom thread up. The bottom thread is ok. I have checked my bottom tension it is ok. I have tried the top tension knob, but when I turn it nothing seems to change. Does anybody have any ideas? Thanks!
Your top tension knob definitely should have an effect. Make sure that there isn't something else in the thread path that might be creating tension of its own. (For example, I have accidently gotten thread wrapped around the spool post) HQ educators suggest that you begin setting the top tension by:
1. Floss the thread into the tension disks to make sure that it is completely seated.
2. Turn the adjusting knob to the right until it is snug tight. Then open about 6 full turns as a starting point. I have found that 4 turns open is more than loose enough for most of my threads on my machine. I also have the bobbin tension set just loose enough that I can't lift the case out of my hand by the thread.
I have at one time replaced the HQ tension disk with a gammil rotary wheel (purchase thru gammil web site). It worked pretty well for a while, then I went back to the tension discs and have had no problems since. Go figure. The gammil wheel requires you to wrap the thread one and three quarters around it, then up thru the spring, under the thread bar, and up thru the thread take up etc.... So instead of flossing, you are wrapping.
I have seen a You-tube video on replacing the original Gammill rotary tension wheel with the tension disk style for better tension control when using a variety of threads. I think using the rotary wheel tension on My HQ would be a big step in the wrong direction.