You will need:
~ a prefold diaper (I used a premium pf here that when ironed measured about 12.5"x18")
~ outer fabric (flannel is good and cheap)
~ elastic
~ thread
~ cutting tool of choice
~ washable marker
~ sewing machine
~ snaps (technically optional)
First iron your prefold, or use a new unwashed one.
Next, lay your pattern on top and trace. I had to line the outer edges up to make sure that it stayed centered while still allowing at least 3/4" outside of the center panel seams (where I'm pointing) for turning/making a casing. I also traced a line just inside of my pattern line because this is a fitted and should be trimmer to fit under a cover.
Then cut, and trim the excess middle layers next to the center panel to reduce bulk.
Lay your outer fabric down right side up, and lay your cut prefold on top of that (wrong side up if you've got one). Cut around.
Mark where your elastic should start and stop, and pin your leg curves. You're going to sew just along these curves for now. Make sure that you line up your start and stop points right on the edge and to where when turned will make for a nice curve, and have at least 1/4" seam allowance the length of where the elastic will go
Next measure your elastic. An easy way to do this is to leave it relaxed and make it the same length as your measurement, plus some extra, then cut that piece in half.
Next, sandwich your elastic between layers within the seam allowance at your elastic markings and pin. Do this at all four points and tack down using a zig zag stitch.
Now turn right side out and faux serge (zig zag) the entire BACK closed. Leave long tails of thread and tie a knot close to the fabric for security purposes. We don't want all your hard work going to waste if the zig zag comes undone.
(My little helper loves the monkeys)
Now it's time to make your casing. Sew down the length of the leg curves about 1/2" in from the edge, stretching the elastic as you go. Don't sew on the elastic! Feel for it between the layers and keep it as close to the outside as possible while sewing.
It's starting to look like a diaper now isn't it?!? We're going to work on the soaker now. Remember those scrap pieces from when you cut the prefold? Take those pieces, open them up and lay them flat all stacked together. Mark a rectangle that fits well within your scraps and pin the inside to keep it from shifting. Then sew along your lines using a tight zig zag stitch, and trim your edges when you're done.
Now, if you're doing snaps grab that piece of scrap outer fabric and use it to reinforce your snaps. I folded mine in half for two layers of reinforcement, and cut it wide enough to fit the width of my snap placement marks, which I also put on in this step using a regular pen.
Add your snaps through these layers. I like that since there's no crossover of the wings, I can use sockets on one side and studs on the other. No wasted extra snap pieces leftover! Now attach the soaker piece to the inside front of the prefold using a zig zag stitch. Since this is for a boy, I attached mine quite high.
Like how the washable blue marker bled so much on the soaker piece? That would be due to my little helper getting ahold of the iron (unplugged and cool) and figuring out that one of the buttons turns out into a squirt gun. :/
But alas, we're in the home stretch now. Just faux serge the front closed, leaving long tails again to tie. Be careful around the snaps, my presser foot had to go over them which isn't the safest for your fingers. To avoid this problem you could just not place snaps so close to the edge. Add snaps to the back wings. PAY ATTENTION HERE, use appropriate sockets/studs on the proper sides so that the diaper will actually snap! Lol Now admire your work!
And the super small amount of scraps leftover!
Now, if you didn't want to use snaps: you would simply attach the soaker in the same way, close it up, and pin on the sides!
Cost breakdown:
Prefold (premium)= $2.16 ($26/dozen when new)
Flannel= $0.33 ($1.99/yd on sale, and I can easily get six cuts from a yard)
Thread= pennies
Snaps= $0.50 (kam snaps sale, even cheaper sometimes)
Elastic= $0.08 maybe
TOTAL= about $3.10
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