Originally Posted by marasmum
this sounds so great!
One thought (I don't know if it has been suggested yet but) - would it not be to our advantage to use new, unwashed (and therefore unshrunk) prefolds when sewing the AIO? In theory, it would probably be easier to sew (fabric is "flatter" - not pillowy like it becomes after it has been initially washed a few times) AND it would shrink in the wash after sewing, therefore forcing the outer fabric (PUL or fleece) to fold in. This turning in would help prevent wicking, no?
Just a thought!
I don't know how it would work with prefolds, but we experimented with sewing the birdseye in not preshrinking it first to see if it would help the legs roll in - it did but cotton shrinks both ways so we lost an inch out of the rise too. Maybe if you cut the prefold a little longer in the rise to allow for shrinkage but cut it regular through the legs it would shrink up properly and you could avoid the decrease in the rise.