Quote Originally Posted by AlohaSandy View Post
Tks this says Coats Rayon? dont know if that makes a big diff.
You are using Rayon thread on cotton fabric? If that's the case that is probably why it's splitting. Rayon thread isn't usually as strong. Also, if you use too long a piece of thread when hand quilting it can fray because of the friction of pulling it through the fabric repeatedly.

I use Coats and Clark 100% cotton hand-quilting thread when I hand quilt as well. I tried Gutterman before and it frayed and knotted too much for me.