Justin thanks for replying. I increased the tension significantly on the bobbin side and then compensated on the top tension so when the thread gets stuck on the spool the bobbin doesn’t even notice it and it pulls it without affecting the stitch. I carefully removed the stitching on my panels and sewed again

It just did it right now dead center of this panel

I just bought the NC twin needle post bed and it’s great! You can even pause one needle and run one side only.

I used the 1/4” volara on this door panel , and it went well. Under the alcantara it’s 3/8 or 1/2”

I ended up redoing it. I’m using a heat activated polyurethane glue 3M 1099 that is really thick to start. Since the glue is 60-80% acetone by weight I can add my own acetone to thin it further to either shoot it with a gun or brush it smoothly. It starts to tack so fast uou often get 1 or 2 brush strokes before you get lumps created. After the glue is completely dry I can position my pieces, without risk and move them over and over again until seams are perfect. Here are some examples of some better pieces I just completed for this job

Good tip Rob. I will use that for the next set.

It’s not defective foam, I think it’s due to the fact that the sew foam is rigid and when it wraps around the edge it props the middle up. I was considering next time sewing/gluing a plastic piping behind the top stitch and pulling it back through the foam like a pull bar but less prominent

Go to local steel supplier and get off cuts