I am sure your assumption that the needle is hitting the plate is accurate. There is a procedure in the manual for lining up the needle. Which I don't have handy at the moment. But you can rotate the shaft and move the needle down by hand if the red emergency stop button is depressed. Doing so will allow you to see exactly where the need is going. I know one of the techs on this board would be able to resite the process. However, I've also experienced problems with needle deflection on certain hats. Especially if you are sewing close to the lower edge. Many of the hat manufacurer's use a thread that is like wire in that area and if the needle hits that wire, it will deflect or break.
Sue
All Custom Embroidery
Sue
All Custom Embroidery
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