I have been wanting to sew my own diapers for more than twenty years. Finally got around to it. Turns out I was using the wrong machine. A regular sewing machine was the wrong way to go. A Brother 1034D Serger is what I needed and now it is very easy to sew flat diapers.
I have tried using single layer cotton and muslin, but they don't have the right feel. Flannel feels better, but it is not quite right, either. I recently bought a yard of 500 gsm bamboo/cotton, but it is way too heavy for a diaper of itself. I ended up cutting it into soaker pads and it works great in that capacity.
Right now, I'm waiting for an order of double gauze to arrive. It seems the good quality flat gauze diapers from adultclothdiaper is double gauze.
Just curious what other home-sew diaper fabrics others have used and how they liked it?