Sew a Cover Using a Borrowed Diaper Cover

• 1). Borrow a friend's diaper cover in your baby's size then trace around it to get the basic shape for your diaper cover. Make sure you stretch it out when tracing it to get an accurate pattern piece. Cut out the pattern piece.
  
  
• 2). Lay the pattern piece on your printed fabric then cut it out. Repeat this step with the PUL fabric.
  
  
• 3). Examine the borrowed diaper cover to see where the elastic has been stretched on each leg then mark those points on your outer fabric. Repeat this process for the elastic on the back of the diaper cover.
  
  
• 4). Paperclip your printed fabric and PUL pieces together. Avoid using pins as they will poke unnecessary holes into the PUL and reduce its effectiveness as a waterproof fabric.
  
  
• 5). Sew a strip of loop tape across the front of the diaper cover. Sew a hook tab on each of the diaper's wings.
  
  
• 6). Sew the foldover elastic all the way around the diaper cover using your sewing machine's zigzag stitch. Stretch the elastic as tight as possible as you sew whenever you hit the marks you made for the legs and back.
  
  

Sew a Cover Using a Disposable Diaper

• 1). Lay a disposable diaper out on your sheet of paper and trace a general outline to create your pattern piece. Make sure you stretch it out when tracing it to get an accurate pattern piece.
  
  
• 2). Remove the front wings and add a few inches to the back wings so that they'll wrap around the front of the cover and secure in place. This is where you'll need to experiment a bit to make sure that your pattern piece is going to work out. Cut out the pattern piece, make a test cover with a piece of scrap fabric, then try it on your baby to see that the wings will wrap around properly.
  
  
• 3). Lay the pattern piece on your printed fabric then cut it out. Repeat this step with the PUL fabric.
  
  
• 4). Examine the disposable diaper to see where the elastic has been stretched on each leg, then mark those points on your outer fabric. You will also need to add stretch to the back of your diaper cover. Mark points along the edge of the back of the cover that are a few inches away from the edge of each wing (they should just about line up with the curve of the leg opening).
  
  
• 5). Paperclip your printed fabric and PUL pieces together. Avoid using pins as they will poke unnecessary holes into the PUL and reduce its effectiveness as a waterproof fabric.
  
  
• 6). Sew a strip of loop tape across the front of the diaper cover. Sew a hook tab onto each of the diaper's wings.
  
  
• 7). Sew the foldover elastic all the way around the diaper cover using your sewing machine's zigzag stitch. Stretch the elastic as tight as possible as you sew whenever you hit the marks you made for the legs and back.