This tutorial will go over how I convert a prefold diaper to a fitted diaper. I am using a brand new unwashed Indian unbleached premium prefold, infant size. You can do this with a prefold that is already washed and prepped or you can use a brand new one like I am here.
Grab a prefold, print the template and let’s get started!
First step is smooth your prefold so the corners are straight. Iron if you need to. Once your corners are smooth and you have as close to a 90 degree angle at the corners as possible it’s time to trace the cut lines from the template.
trace and cut
Once everything is cut out you will want to head to the serger. If you do not have a serger you can use an overcast stitch along the edges or fold in the raw edges 1/4 of an inch on each side and top-stitch 1/8 of an inch from the edge to close and secure.
Line the raw edge of the wing up with the blade of the serger. You do not want to cut anything off here so disengage your blade if you need to. You want to keep the fabric as straight as possible so you can serge the inside corner.
serge step 1
When you are serging you will gently push the fabric with your left hand and guide with your right to keep it straight at the blade.
serge step 2
Repeat this for all four cut outs.
Use your preferred method for securing tails. For these I like to fold the tail over the stitching and use a tight zigzag stitch to secure, then trim close to the stitching.
With the outside of the diaper facing up, pin the sleeves together.
pin sleeve wrong way
Serge the long edge of the sleeve. You want to cut off about 1/8th of an inch here.
Secure the tails like you did at the cut outs and turn right side out so the sleeve is on the inside of the diaper. Center the sleeve and adjust it until you are happy with how it looks. Pin through the center of the diaper.
Using a ruler you will want to measure in 3/4 of an inch from the outer edge at the leg curve.
Draw your casings along each leg.
Stitch along these lines with a straight stitch. Make sure to back-stitch at the beginning and ending of these stitch lines to secure your thread and reinforce the stitching.
Cut your elastic. If making a OSFM prefold conversion you can use your favorite OS leg elastic lengths. Adjust as needed for your baby or the size of the prefold.
Using a bodkin begin to thread your elastic into the casing.
Insert the elastic until the cut edge is lined up with the serged edge of the casing.
thread and stop
Stitch along the bottom edge of the serging to tack and secure the elastic in the casing.
Continue to thread the elastic through the casing to the other end. Pull elastic so the edge secured with the bodkin is flush with the serging. Pin the elastic into the casing to secure.
end of elastic
Remove bodkin and stitch across the elastic.
elastic sewn in2
Repeat with other leg.
Using the free sandwich soaker pattern cut out and serge up a booster or doubler if desired.
Slip insert into sleeve.
All done! Grab your favorite cover and put your converted prefold diaper on your adorable baby and admire your handiwork ????