Ok, been doing more research... here is what the industry expert is using for this same application:
Juki 563 w/either 92 or 138 thread
Consew 733R w/"5-chord" thread
Part of my dilemma has been that I'm trying to find ONE machine to do what everyone else seems to do with two...
The absolute minimum thread size I need to use for the structural components is 207. Most places are saying that if I need one all-around machine, high-lift walking foot, that can use 207 thread, then the Juki 1508NH is what I crave. Other than that, I'm hearing I'd be better off with two machines.
While 2 machines would be ideal, I don't think I have the budget at this time... I'm looking at between 2-3k for a new 1508NH w/motor, table, etc, which is still high for what I have budgeted. Used class7 machines seem to start about there, and it would be really impractical to sew the smaller stuff on a big machine, so that won't work for me... a local shop here has the 1508NH machine with a heavy duty table and a 3/4 horse servo motor... That's definitely where I'm leaning.
If business is good and later down the road I can afford a class 7 monster and run "5-chord", all the better... but for now, all of my research has pointed me toward the 1508NH.
When I say thick work, I probably mean 1/2" to 3/4", layers of 600 denier cloth, 1/4" foam, 3,4,5 layers of webbing, and sometimes some 'ballistic' pack cloth. I'll also be sewing velcro, zippers, things like that... but that's not the thick stuff... And I definitely need a flatbed machine...
Does anyone have any experience with the Juki 1508NH... particularly if you've used it with 207 thread???
-Ryan