rtbcomp
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Make sure you don't have the tensioner on the spool set to tightly. You just want it tight enough to stop the spool from unwinding its self.
Hi, I realise that, but on slow speeds you have to have it set on the slack side because the motor struggles, but if you increase the speed the wire drops off the reel when the feed stops!
I was wondering about fitting a spring loaded arm to take the slack, or some means of catching the wire so it doesn't fall beneath the spool, or maybe a flap rubbing lightly against the spooled wire.
Another thing I'd thought of is that the pinch roller may have worn barrel-shaped, the 'belly' may contact the capstan, and so not pressing on the wire hard enough.