Thanks guys. I will try a larger needle. I have some DYX1 7X1 300 needles and some 330 samples on the way. I will try them. The machines stitch fine with the .8mm thread and the supplied 230 needles. I thought there may have been some sort of interference between the arm of the machine and the bobbin carrier with the 1.1mm thread. I thought it might require grinding away the bobbin carrier or something like that to allow thicker thread. Could be wrong. We'll see.
I have been told by a needle company rep that a 250 needle should handle 1mm+ monofilament. Whatever that is - fishing line?