E.R.
Hi C., I started CDing my youngest when he was 4 months. Originally I bought some prefolds and plastic pants, but after a couple of weeks I started sewing my own. I'm expecting our 4th in Jan and will soon start sewing for him. Luckily potty training is going pretty well w/the 2 yr old!
I've made fitteds and covers and the aio/pocket types. I love the ease of the pockets! But when they are tiny I think having the separate cover helps keeps things in better!
I've always used PUL as my outer layer or cover. You can make a real simple cover w/PUL and some Fold over elastic and some kind of fastener.
I guess it really depends if you are going for cheap or just earth friendly? I'm all about being thrifty, I can't say I choose to CD because of the enviroment (that's just a bonus). For me flannel works great and is inexpensive! You can buy white diaper flannel at walmart and then get prints for your outer layer of fitteds. I do like to put microfleece as my inner layer in pockets if I can afford it. I get it at joann's w/their 50% off coupons. I also use microfiber inserts in a lot of my pockets. I bought a pack of microfiber towels made for car drying at Sams Club a couple of years ago, they are great, not sure if they still sell them! I don't like the microfiber agaisn't baby's skin though. I've used it in soaker layers too, but put something else for top layer. Mostly the only things I order online is PUL, touch tape or aplix and sometimes some FOE. Sorry for going on and on, email if you want to ask anything else! ____@____.com ~E.