"What keeps happening is that the thread keeps coming off the second tension knob , and spooling around the post that it's supported on." Are you able to post a picture of this?
The machine will definitely sew thinner material when set up correctly. First thing I would do is check the owner's manual to see that the needle hook timing is spot on. I supported a mirror on a board with three screws, so I could see the needle and loop action without standing on my head.
This help number for Tippmann may be useful: Need Help? 866-286-8046
Here are some miscellaneous thoughts on the Boss (no particular order)
Always make firm and complete strokes up and down with the hand lever. Jerky movements or stopping then starting (particularly when about to enter or when in the material) may cause issues such as missed loops/stitches or double loops.
Most importantly, if the machine locks, binds or the hand lever doesn’t want to move up or down for any reason, just stop immediately, no force. Any other action will most likely do damage. Think it through. If the material is locked in place, just cut the threads, clean out the clippings, look for the cause (thread path issue i.e.) and then continue.
Double looping is usually caused by the primary tension being too loose. This machine seems sensitive to tension settings, in my opinion.
See the separate sheet on adjusting the primary tension wheel and the secondary tension’s affect on it.
The primary tension is named that for a reason. It’s usually adjusted twice what the secondary tension is adjusted. i.e. if the primary, knurled, round nut is turned one-half turn, the secondary is turned one-quarter turn. You’ll develop a feel for it. Feel how the top and bottom threads feel now for reference.
Before threading the needle, cut the end of the thread on the same bias as the twist of the thread. That’ll leave a small, sharp point on the thread.
To get extra top thread, pull it from the needle side of the “F” Guide Post, or hold the hand crank back and pull from the Needle Foot.
Lubrication is critical; follow the instructions in the Owner’s Manual.
Put a drop of oil in the groove (in the body casting) that the shuttle rides in anytime the groove seems dry to the touch. Makes a huge difference.
Use a clear, quality, sewing machine oil like SEW-RITE Precision Machine Oil from Tacony.
Check the needle tip for burrs often and check the thread path frequently, particularly before a critical sew until you’re comfortable with the machine.
Keep the shuttle area meticulously clean, the tension wheel and the tension discs as well.
Adjust the stitch length in increments. I believe it’s best done with the needle out of the material… not sure, didn’t experiment with it.
Use your mirror stand and a mirror to see how each stitch is forming, at least until you’re comfortable using the machine. It will give you a heads-up if a problem is developing or a stitch is going bad. (i.e. hook missed the loop, hook picked up a double loop). It’s an excellent tool. If the hook misses the loop, you can often put the needle back into the missed hole and carefully continue. Haven’t had a missed stitch or double loop since the timing was fine-tuned.
Machine timing first and thread tension second are critical factors in getting a good stitch. Feel how the top and bottom threads feel now for reference.
Refer to your needle-thread chart(s) when changing thread size. As we learned, mismatched needle and thread combinations can cause big issues.
When turning a corner, the owner’s manual recommends moving the hand lever fully to the top, lifting the foot and then turning the material. With the timing as good as it is right now, it wouldn’t surprise me if the material can be turned with the needle in the material… once you see the hook has caught the loop. I didn’t try it.
When you replace or change a pressure foot, put the screw in to first resistance, then set a firm piece of leather under the foot, loosen the screw, and then tighten the screw. This insures the foot is flat and feeds as best it can.