You really don't need that entire amount of fabric, in fact the largest diaper size needs (2) 16 X 20 inch rectangles. But, in case you're buying yardage of fabric at the store, 1/3 to 1/2 yard will keep you in the safe zone. Best idea: measure the pattern size you're using and figure out exactly how much you need/want. It's never a bad idea to have extra fabric. Then you can make 2 pairs and keep on on hand for a baby shower!
1/4 '' elastic for the legs (any kind)-see pattern 3/8 '' or 1/2 '' elastic for waist (any kind)- see pattern
Cutting:
Print a copy of each pattern page
Trace the diaper sizes you need onto blank sheets of paper so you have patterns for various sizes. This saves on printing and plus, it's easier to reference the original pattern when you need to.
Label your patterns with appropriate info so you don't mix-up the sizes. If you make changes to the sizing or with the elastic, note that on the pattern along with the date you made it, or what fabric you used, or whatever info will help you out the next time around.
Fold your fabric in half, lay the pattern piece on the FOLD (where marked) and cut out ONE for each pattern piece:
Okay,
With RIGHT sides of your fabric together, sew the front and back pieces together. Line up the sides and sew down both sides. Line up the bottoms and sew that together too, in the places marked below:
Serge off your seams, do a zigzag stitch, or leave them raw (serging and zigzagging makes your seams stronger and keeps them from fraying over time).
Serge the top of your waistband, all the way around.
If you don't have a serger, iron the waist band over 1/4 inch, just as you did for the leg holes.
Iron out all of your seams:
Then iron casings for the leg holes and the waistband. Iron the LEGS over 1/2 inch. Though we're using 1/4 inch elastic for the legs, it's good to give yourself a 1/2 inch casing. This will make the project easier, the safety pins will go through better and thus, your life will be happier.
Your leg holes should look like this.
Okay, iron the waistband over 3/4 of an inch to create a casing. Note: I prefer using 3/8 or 1/2 inch elastic in my waistband; it just looks better to me. This is why the casing is 3/4 inch wide. If you want to keep it simpler, make your casing 1/2 inch wide and use 1/4 inch elastic in the waistband just as you did with the legs. Either way works fine.
Stitch down your casings in the waist and in the leg holes. MAKE SURE you leave a small opening in each so you can get your elastic in and out.
I use pins to mark a Start and Stop point, so I don't forget to leave a hole:
Sewing the leg casings can seem tricky because your creative mind will tell you to make it as smooth and beautiful as possible. IGNORE your gut! It will (almost) never happen. Because the legs are cut on a curve, it's near impossible to fold the edge over smoothly without trimming the edge in (which you don't want to do here) or using bias tape (which has more "give" and is meant for curves). But with a diaper cover it really doesn't matter because the leg holes will be gathered and you'll never notice the tiny imperfections in your seam. So..start sewing from your Start point:
And, without being overly obsessed about it, use your left hand to push and pull and to keep the fabric as smooth as you can:
Don't stress over it but do your best to keep a 1/2 inch casing all the way around. This is another reason we made the casing a 1/2 inch instead of a 1/4 inch. More room for error!
When you're done, your legs should look like this:
Now add your elastic.
Zigzag stitch the elastic ends together.
Do Not sew the leg casings closed til you look at the two legs together.
If both legs look even, sew the casings closed with a normal stitch.
Follow the same steps and string elastic through the waistband.
That's it!
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