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I figured I'd show my process, seeing that I'm in the midst of sewing a bunch of XL diapers (I'm using the Sized Square Tab Template- XL pattern).
Cut fabric with the stretchiest part of the Pul goes across the waist (horizontal). For a pocket diaper you need a cut of the Pul outer and also a cut of your inner fabric (mine are alova suede cloth or microfleece).
Sew on loop fabric for the waist and/or add snaps if you're doing snaps or a snap down rise. Reinforce your snaps by using scrap fabric behind them. I just added loop because I'm doing hook and loop diapers without a snap down rise.
Pin inner and outer fabrics right sides together. Mark where your back elastic will be.
Sew inner and outer fabrics, right sides together, leaving it open where your pocket will be.
Turn right sides out.
Fold down the inner fabric where your pocket will be twice so the raw edge doesn't show. I tucked a size label under and then sewed a straight stitch to finish the edge. It's not perfect, but I wasn't particular about it.
For the Pul where my pocket will be, I also folded the fabric down and sewed a straight stitch. That will also function as an elastic casing so I leave enough room to feed an elastic through.
Mark where leg elastic casings should be, then sew your casing.
For the leg and back casings, cut your elastic the length you want it to be and feed it through the casing. Tack the first end down, then stretch it to the other end of casing and tack that end down (don't catch the safety pin or bodkin, it'll break your needle). I use a safety pin or a bodkin to feed it through. Leg elastic is tricky because you don't want it too tight (makes diaper too small) or too loose (leakage). I actually measure how much elastic I use on my diapers and then see how they hold out against poop, then adjust the size to be smaller if needed. I record how long my elastic is for the diaper pattern I use (making sure to make the casing the SAME size each time). It's easier to take in elastic than it is to replace elastic that is too short. Some people figure out how long to make their elastic by holding the elastic over the casing and pulling tight... I think I was pulling them too tight which resulted in marks on my child's legs so that's why I decided to try to measure it out and experiment instead. Measuring it all out also helps me make sure all my diapers have the same length elastic.
On my back elastic I used a thinner elastic because my casing was a bit small for the thicker elastic I like for the legs.
These elastics ended up being a bit too long so I'm going to need to take them in.
I added a snap to put on my removable tabs:
Stuff the diaper with your inserts:
And here's 4 new XL diapers for our stash!
Gosh it's hard to get action shots with a 22 month old! I've got a few more coming soon, as well as two that are embroidered. I'll be posting about those soon.