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I did the tension test - needle thread doesn't show on the bottom and bobbin thread doesn't show on the top - but I'm getting a line of puckering about 1/4" inside the seam. I just don't know what is wrong.
Reply
I've tried to recreate the problem, but with no luck.
Obviously something, somewhere, is a bit too tight. So I would suggest the following possibilities:
Try a new, out of the package, needle. An imperfect needle can cause all sorts of problems.
Check the thread path to make sure that the thread isn't wrapped around something (like the spool pin or uptake arm) putting a wee bit extra tension on the needle thread. Though clearly it's not enough to unbalance your sewing machine tension, it could be just a hair too much.
Reduce your needle tension, just until the point right before the stitch becomes unbalanced.
Press to set the seam. Put the stitched patches on your ironing board and press the seam as it was sewn. THEN, open it up to press the seam allowances either open or to one side, your preference.
I hope these suggestions help. If not, do re-submit your question with a picture. The extra info a picture provides may help us come up with a solution for you!