I'm really excited about this project, as it's not only the first time I'm making a diaper, but it'll be the first time (since I was 2) that I'll get to wear one. I wanted to blog about it, but I'd have to wait 5 more days and I'm too excited to wait! I thought I'd share my process in case it might help anyone else out.
First I bought some large pieces of fluffy fleece at goodwill (one was a blanket and the other just a large piece of fabric). As I am not currently interested in using, I only took the feeling and color into consideration, but a waterproof liner layer might be nice for others.
After scouring my house to find the one paper bag that didn't get recycled, I made a fitted diaper pattern. I had to tape on pieces to the long sides, since my bum is wider than a paper bag. The pattern is 40" on the back tabs, and 15" in the front, so there's about 5" of overlap for each tab. It's 7" at the narrowest point, and I guessed on the curvature of the leg openings. I may suggest that a steeper curve (the long parts being thicker) would be better for someone who will use theirs, the shape fits me a lot like bikini style underwear in the back.
I traced the pattern onto my doubled over fleece (forgot a picture at this step, sorry), pinned it (that's important!) and then cut it out.
I wanted more padding than the 2 layers of fleece, so I measured and cut two 6"x15" rectangles and pinned them in the middle. The soaker panel is pinned on the "wrong" side of the fabric, once it is sewn on (to just one layer of fleece), and the whole diaper is sewn almost all the way around, it'll be turned inside out (so the soaker panel is inside), and sewn up to finish. Alas, I'll have to update sewing steps later, my machine is on the fritz. >.<
Lemmie know if you have questions or suggestions, and I hope this helps somebody! Also, in previewing this post, the pictures look huge, even though I resized them. But I'm not computer smart (I mean, I'm a mac user, afterall :P)so I apologize if they're unnecessarily large.