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Thanks to Mr. Bob Fowler on YouTube, I know exactly what the problem is. Will have to find time in between real 9-5 work today to go fix it. There's a mechanical CAM which controls stitch length here, and it clear is frozen or not moving very well. That's just a lubrication issue. I did not lubricate inside there, looks like there are three contact points (should be accessible from the front panel). Since nothing was broken (or likely to break) on these machines, it's almost 100% just not enough lubrication.

youtube.com/watch?v=yBvHGsqC-O