So I decided to go with what I had plus mixing and matching of a few things that made the most sense to me. I followed this tutorial for basic construction, with a little splash of this one, and finally used the idea of a waterproof layer from here. Phew. Got that? It took a few different tries to figure out my preferred method (six, actually) but this is how I did it.
I designed my own template by cleverly drawing around an Always and adding a seam allowance, then cut two cotton outer fabric pieces (pre-washed, reclaimed cotton from here), and one from PUL (a waterproof fabric often used for sewing the outside of reusable baby diapers).
I then made inner cores from multiple layers of cotton flannel, either some really old yardage I've had for forever, or reclaimed from a thrifted and washed mens cotton flannel shirt, or from layers of scrap 100% cotton batting. These were cut to match the center shape of the liner but about 1/4" smaller. I zig-zag stitched around the edges to make a little panty liner thing as seen below:
Then stitched that down to one layer of the cotton on the wrong side.
Then there was a bit of trial and error in figuring out the order and layer of fabric (right vs wrong side and in which order), but I was aiming to have PUL on the bottom (right side out), then the cotton+flannel layer, and then the final cotton layer on top (right side out). I succeeded once. Ha.
I think it was PUL right side up, cotton wrong side up, and cotton+liner wrong side up. The easiest place I found to leave the turning hole was along the top edge, and when I turned everything right side out I made sure the have the PUL on bottom and the unstitched cotton on top. This means the final layer from top is: cotton, cotton, flannel, PUL. Make sense? My machine did NOT like sewing directly onto the PUL but had no problem forming stitches when the PUL was on the bobbin side, go figure.
On some the order ended up being different (cotton on both sides, PUL in the middle) making it difficult to know which side should be the top, so I added a small "handmade by" label on what should be the bottom. I also added a small row of stitches to some of the earlier iterations to hold the flannel core securely in place as I hadn't stitched those the the middle cotton layer. I also top stitched all the way round very close to the edge to close the turning hole. I didn't add any stitching down the middle as I was afraid it would lead to moisture wicking through the PUL layer.
So far I have made 6 pads, all very slightly different but hopefully functional. One is all cotton (no water proof fabric), one is backed with no-pill fleece. The rest are all iterations of what I showed above. I added contrasting plastic snaps to the wings in either yellow or red.
My fellow Quilt Guild and sewing bee member, Margaret, also sent me 6 pads! I need to add snaps to these and then they are all done :)
I'm planning on making at least 6 more before the deadline (delivered by November 15th!) but I think I'm going to switch to using a different pattern (the second tutorial) using either fleece or PUL as the bottom layer. It's kind of fiddly to cut out all those layers in weird shapes but so satisfying to see the finished product!



