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Needles and thread all sorted out. With Greg's help over at Keystone I've replaced the ancient clutch motor with a new servo and the Adler runs great.

The bobbin case/thread issue was caused by a "slipped" gear. The bevel gear on the vertical bobbin shaft was a mm or so low allowing the bobbin mechanism to rise as it was driven by the main shaft gear. Moved it up removing the vertical slop and all is well.

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