If you aren't already, try using an 11/75 needle Ronny. I find that size is best for FSL.
As for your bobbin, when you refill it make sure you start winding it very evenly holding the loose end, then stop winding and cut the loose end off.
Hope this helps,
hugs n roses, me
I think the needle sticking when going through a dense design, is just the nature of the beast (or sholud I say beauty when talking about our embroidery machines) Both of my machines do the same thing.
It's always a bad idea to sew one design on top of another. That's why in most software you can place them that way and remove the underlying stitches (those in the lower of the 2 designs) so the density of the combined designs is not increased. Sewing slowly might help, but isn't a real solution.
As to the second problem: do you wind the first bit by hand so it 'takes' better when you let the machine wind it. I did at first and that made it stick. If not, I wouldn't know what causes it.