You sound like an experienced sewer. Me, too. But... what I found recently was that a wisp of thread (hard to even see it was so fine) had gotten caught in the upper tensioning disks. I dug it out (carefully of course) and the problems I'd been having disappeared.
Hope this helps.
Check this solution:
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If the loops are forming on the bottom it is the TOP thread tension you need to check. Make sure it isn't too loose. Also is the needle the right type and size for the fabric? Check the stitch out on plain cotton fabric if a tension adjustment doesn't fix it.
The TOP thread effects the UNDERSIDE of the stitch and the BOBBIN thread effects the TOPSIDE of the stitch :)
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Thank You so much. I held the thread between my fingers on the outside the spool and the machine sews great again. Something has loosened up on my spool holders.. Thank You... I think now I can fix it!!! You are great!!! Sandy
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