That's great if you use the pattern! When licensing is available, you might think about doing something like KHW does and just sell them and donate the proceeds.. at least that way your materials are paid for. Or, for evey one you sell, you could donate one... you wouldn't make an ounce of profit, but your supplies would be covered.
I can't even imagine how long it would take me to finish 40 diapers! Takes me an hour or more for one diaper and I usually get about 40 minutes a day to actually sew without little hands grabbing at me or a little person crying "no work mama!" And some days, there's no sewing at all because she gets so upset if I even move toward my sewing area. Man what I wouldn't give to have some family near by for a small break here and there.
Why are you sewing anyway?! If I were in HI, I'd be sitting on the sand somewhere sipping a strawberry daquari and I'd never move again.. EVER. I'd just be big and fat and lazy in the sun.
Does Nathan let you sew without a fuss? Oh wait! He probably still naps doesn't he? I long for the days of naps! Seriously though.. it's an addiciton isn't it? Sewing diapers.. even though I feel like they take me a long time to finish, they are really projects that dont' take long to see results and it gives you such a sense of accomplisment
aplix through a co-op is a much better price. I'm always shocked at how fast I can go through aplix. And, you know, of course, I prefer knitted elastic (really hate polybraid and woven elastics) for a turned diaper.. if you plan to use a lot, a co-op is totally the way to go.. or even http://www.diaperfabric.com/store/Ws...mbs=No&Thumbs=
.. 22 cents a yard if you buy by the yard or 10 cents a yard for a full roll. I ususally pick mine up at wal-mart because I forget to order ahead of time and need it right away but it ends up costing me like 60+ cents per yard.. that's kinda pricey per diaper for just the elastic when you are donating the diapers.
Oh check and see if you have a yahoo freecycle there.. and ask for diaper flats. Most mamas had some around for burp cloths or a ton that never got used at all. They are usually birdseye and are easy to chop up into wonderful soaker pads. I'd go with like 4 layers of birdseye and a layer of sherpa myself for an average soaker. Worth a shot.