So, I made a trip to Jo-Ann Fabrics and bought me some *link*
Terry Cloth and used my 40% off coupon that they always have at the store, plus my 10% off coupon for my online business. I got a bit over a yard for less than $4 =) yeah baby!
Than, I took my diaper inserts that I already have, chose the Alva brand for comparison, and measured it 12.5inL 5inW and started to cut it up, works up really fast if you just lay your insert down and just keep going. I did long enough strips that I just had to cut in half length wise to get 2.
With just over a yard, I was able to get 30 pieces with some scrap left over. I will be using the scrap for a Swifter Floor Cleaner cover ;)
I sewed 2 pieces together, layering them on top of each other, leaving an opening at one end, like you would a blanket, than I would turn right side out, and tuck in the opening, sew closed, and keep going to make a boarder.
I do not have a searger at the moment, plus I prefer the security of the double sew on an item that will be used, and washed a lot! so you could probably do this with a searger with out having to flip right side out and so on.
Ending Result:
Comparison to an older bought Alva Insert:
Comparison of the corners, and stitching: