Made my ds flannel family cloth out of flannel I got for fifty cents a yard LAST year on black friday. I folded it and cut it with my rotary cutter to be as long and as wide as "four squares" of toilet paper. I zig zagged around the edges (two ply). It is holding up GREAT and he loves it. He has this FEAR of the toilet over flowing, and I told him that it's a LOT less likely to happen with family cloth because there's no TP to plug up the potty.

Saves me easily three rolls of toilet paper a week, too (the boy went through it like mad).

Sorry, that may be more than you wanted to hear!

But, yes, that's how we did it, cut with a rotary cutter and then zig zagged.