How to Make a Simple All In One Diaper
and Prefold Diaper Cover

An All in One (or AIO) cloth diaper is one that contains the cover and the absorbent lining together as one package.  These diapers are good for outings and for babysitters or grandmas who don't know how to put on the prefold diapers and covers that most cloth users have today.  Most of the these AIOs are quite expensive and not very absorbent.  They can run from $10-15 each.  I have here simple instructions for how to make one at home using "recycled" products.

I made a pattern that is similar to a fitted diaper, tracing a cover I already had.  I used some scrap fabric for this purpose.  Then I added 1 inch all the way around for allowance for bunching and stuffing.

The outer shell is made from fleece.  Fleece will naturally repel moisture while being more breathable than vinyl covers.  Even with a soaking wet night diaper the fllece is barely damp.  You can also buy other types of waterproofed fabric from a fabric store. One woman suggested using raincoat material.

Then I took a washcloth (left over from when I used cloth wipes) and folded it into thirds and sewed it like that. Then I sewed that to a bar towel (you can buy a big packet at WalMart for almost nothing) that was already cut to the shape of the diaper. You can also use an old kitchen towel.   The top layer, the part that touches the baby's skin, was made of an old flannel blanket.

All the layers (fleece, bar towel, and flannel) were cut to the same shape and then I sewed around the whole edge first with a normal straight stitch, then with a surger-type edge finishing stitch to keep the edges from unraveling. Then I sewed a horizontal line just above and below the washcloth to anchor the layers together.

Next I sewed the velcro on front and then made tabs with curved edges like the Gerber covers have. I have found that these types of tabs stay on way better than other styles, and also allow for the greatest size variation as the baby grows, while still keeping a snug fit. Sew around the edges of the tabs to keep them from unraveling in the wash with the same surger-type stitch that's used on the edges of the AIO diaper. Also I set the fuzzy part of the velcro strip a little below the waist line to prevent rubbing on the tummy, another flaw with some diaper covers.

Then I just sewed the elastic on the leg gussets from the velcro tabs to horizonal velcro strip all the way around on both sides, as well as the back of the diaper, with a zig zag stitch, pulling for tension as I sewed. My friend pointed out to me later that it's not nice to have the elastic next to the skin, so next time I'll probably sew a binding over the elastic, or find some other way to cover it up (see below).

How to Make a Fleece Cover

Using the same pattern, I have also made prefold diaper covers
out of waterproofed fleece.  I cut a pattern similar to the one above with 1 inch extra all the way around the fleece layer.  The decorative cotton is not necessary but makes it look pretty!  Then I pin in the areas where I'm going to run my elastic.   This is a new trick I've learned since sewing the AIO's above.

Next I run the elastic through the tube using a safety pin.  When the free tail end is almost through the hole I anchor it with a few backstiches.   Then I run the rest of the elastic through and anchor it, cutting off the little extra elastic and of course removing the safety pin.

Then I repeat this step for the other leg and the back of the cover.   Finally I pin around the edges of the rest of the cover (the more pins the better it turns out) and sew.

Finally I add snaps or velcro (either is fine) . . .

. . . and looks like we have one happy customer, with room to grow!

(and in case you are wondering, yes, that's what a person's house looks
like most of the time when you have a toddler around!)

How to Convert a Chinese Prefold Into a Fitted Diaper

Click to enlarge

*It may be prudent to make the first diaper from scrap fabric first before you cut into your prefolds. 

1. Wash and iron the prefolds so they are flat.

2. Starting about 2 inches from the top of the diaper, draw a crecent moon shaped line in and then back out 2 inches from the bottom of the diaper.  At the thickest point, the crescent shape should not cut into the central panel of the diaper.   Ideally, leave about 1/2 inch on each side of the central panel.  Then cut the crescent shape out.  Use the cutout from the one side as a pattern for the other side, so that both sides are a mirror image.

3. For an added touch, cut out microfleece the same width as the central pannel of the diaper and sew into place.

4. Cut out strips of pre-washed fleece that are 3 inches wide by as long as the diaper is.  Sew the fleece along one side of the cut out part.  Then fold it over to make a tube for the elastic. Start pinning the tube for the elastic 3 inched from the top of the fleece on both sides.  Sew to secure.

5. Pin the end of 1/4 inch elastic with a diaper pin, then run through the tube.  Sew across the elastic in two places on the pin end. Then while holding the secured elastic end down, pull the elastic in the free end until it is all the way stretched out, but is not bunching the tube.  (In other words the total length of the extended elastic should equal the length of the tube.)  Hold the elastic and sew into place.  Repeat on the other side.

6. Finally, sew down the open ends of the fleece above and below the elastic.

Notes:  You can add velcro or another form of closure if you want, but I prefer to just secure mine with a Snappi or pins.  Velcro tends to rub in the wash and wear out the diaper fabric faster, not to mention the risk of it scratching the baby.

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