The diaper in this Instructable is a fitted pocket diaper with hook and loop fasteners. I like pocket diapers because you can remove the absorbent liner for laundering so it gets cleaner and dries more quickly.
Of course prices will vary, but these diapers cost us about $2 or $3 USD to make. It sure beats paying $15+ per diaper! Also with these diapers you will need a waterproof outer layer, either PUL or wool.
Step 1: Materials List
1 yard of flannel (any kind, color, or style) OR 1/2 yard of flannel and 1/4 yard fleece or 1/4 yard of waterproof PUL (if you use waterproof fleece or PUL you won't have to use a cover over the diaper.)
16" of 3/8" elastic
4 3/4" Loop side of hook and loop fastener
2 pieces of hook side 2" X 1 1/2"
Ruler or Yardstick
Tailors chalk or fabric marking utensil
1 Prefold diaper (for pocket insert)
NOTE: There are many ways to make your diaper template. You can trace a disposable and add 3/4" to all sides. There are also many websites dedicated to helping you draft you own pattern. For our pattern, we used a store bought sewing pattern for a diaper cover and modified it a bit.
Step 2: Preparations
2. Trace template onto fabric. You will need 4 layers of flannel OR 2 layers of flannel and 1 layer of fleece (the big side will become the back of the diaper and the small side will be the front).
3. Adding pocket elastic flap: This is very hard to explain, so please use the pictures for reference. Line your yardstick up with the narrowest point of the crotch and the back of the diaper. Trace 1 inch past this back line. Repeat on the other side. You will end up with a tab that is 1" tall as shown in the picture. This step is important to do because it allows for the elastic to be properly installed later in the process. It would also be possible to add this extra flap onto your template.
4. With scraps left over from cutting out the fabric, trace the wings from the diaper to make the hook protector. This will prevent the hook side from snagging the other laundry in the washing machine.
5. Iron all pieces of fabric.
6. Cut your 16" of elastic into four 4"pieces.
Step 3: Sewing on hook and loop fasteners
2. Sew on the loop side of the fastener to the front of the diaper (see picture).
3. To make the laundry tabs: Hem the straight side of the tabs. Hem it again so there will be no raw edges or fraying after laundering a few times. Cut off the excess at the bottom of the hem.
4. Pin tabs to the wings. To sew them on, make sure you leave the straight hemmed side open because it will need to flip over the hook side.
5. Sew your 2 inner layers together. Make sure you sew everything, including the 1" flap that will make the pocket elastic casing.
6. Choose a layer of fabric that will become the innermost layer, closest to the baby's skin. Sew the hook side onto the inside of the wings.
7. Sew your 2 outer layers together like the inner layers. If you're using fleece you won't need to sew the two layers together, because there's only one.
Step 4: Putting the pieces together
2. Measure 5 1/4" from the front of the diaper and pin the elastic as shown in the photo (don't stress too much over this step, we're making diapers, not watches). Lay elastic flat with no tension and pin down the other side.
3. Tack down the front of the elastics using the sewing machine. Leave the back pins in place.
4. Take your 2 diaper sides and put them together, with hook and loop sides facing each other, elastic facing out (right sides together).
5. Sew the diaper together making sure to not sew the one inch flap down. You must leave this open, it's very important. Also, make sure not to sew the leg elastic down. When stitching around the crotch area, simply move it aside as shown in the photo.
Step 5: Installing pocket elastic
Take a 4" piece of elastic and tack it down directly below one of your 1" flaps. You don't need to stretch the elastic, but the fabric will bunch up under it because the elastic is shorter than the flap. This is exactly what you want. Once it is tacked on both ends flush with the 1" flap, do the same thing on the other flap (the other side of the diaper).
Now comes the tricky part. Fold the flap over the elastic and stretch it out straight as you sew it down. Make sure not to sew into the elastic, but keep just outside it to make a nice tube for it. Do this to both flaps.
If you did it right, you should end up with a really stretchy, wrinkly back of the diaper. This will work to keep the insert from coming out on accident.
Step 6: Finishing the diaper
Also, when flipping right side out, be sure that all edges are turned all the way out. You can even use a knitting needle to get into tight spots.
Now it's time to sew the pocket. The pocket seams serve two purposes. 1) Keeps the insert from sliding around to where you don't want it and 2) makes a casing for the leg elastic.
1. Start with your diaper rightside out. Sew one straight line starting at the edge of the loop side and ending 3 inches from the end of the diaper. DO NOT sew any part of the elastic (remember, the pin's still in there). Repeat on the other side of the loop fastener (see photo).
2. Finishing the leg elastic: There should be room enough between the back of the diaper and the end of the pocket seam to reach in and feel where the elastic is pinned down. Holding elastic firmly in place, carefully remove the pin. Don't let go of the elastic.
3. Now take the elastic and stretch until the leg gusset is desired tension. Tack down with the sewing machine (don't stress over this step, once again we're making diapers, not watches).
Repeat on other side.
Step 7: Insert the soaker in the pocket
The soaker is removed from a soiled diaper before washing and replaced before a clean diaper is put on the baby.
For my soakers I am using a prefold cloth diaper folded into thirds. You could just as easily use a piece of an old towel or anything else absorbent.
Simply take the prefold diaper, fold it in thirds, and shove it all the way to the front of the pocket.
Also pictured is the hook protector laundry tabs. When you want to wash the soiled diaper, simply flip the fabric tab over and it will protect the other items in the laundry from becoming snagged.