I've been looking for a good weed whacker for about 25 years, and I've yet to find satisfaction. The gas ones are over kill for residential purposes. Unless you have a really small yard, cords are a pain. And I've had a hard time finding a rechargeable one with a rechargeable battery I'm happy with. Price isn't necessariy a determinig factor either. Right now I have a cheap Black and Decker that's about as good as anything I've had, but still not great.
With regards to your problem, it sounds like the spool may not be fitting on properly, either because there's some trick you're missing when putting it on, or there's been a manufacturing defect. It may have something to do with the way you're feeding from the spool through the cord exit. I've had some that were really finicky this way. If all fails, do what I do with stuff I don't want. Give it to the father in law and buy a new one. In any case, take heart, you're far from the first person to wage a frustrating fight with these things.
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