Good news! Success!
I was able to get it to consistently sew!
The problem was in fact the Shuttle Carrier. My machine came with lots of parts, including an extra bent shuttle carrier, i figured i had nothing to lose and i used a punch and various tools to bend it back into shape. I then cleaned, filed the burs and polished it with Autosol and success! it works perfectly!.
I should mention, i had tried everything. My machine came with 2 extra rack boxes, one extra bearing, one extra short rack, 2 extra long racks, extra bottom plate, extra throat plate and assorted screws and hardware. None worked until i beat that old shuttle carrier into shape.
Now, i really trying to understand whats different with the other 2 shuttle carriers, perhaps i can make them work too. perhaps they are ever so slightly deformed and are causing an issue.
As for the throat plate, mine is really worn on one side and not on the other but using the non worn side makes it bind and the other worn one works perfectly. Weird.
Andre