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First of all, most babies slim down once they get active. I've heard of chubby babies actually going DOWN in diaper size when they shoot up- even more common is to fit into the same size for a long, long time. Of course, this is more the case for chubby toddlers- it sounds like your son is just big all over, since he's about the size mine was at age 3 (when we were working on potty learning.) Still, he might stay in the same size diapers for the next 2 years.

If not, try doing a websearch on "adult cloth diapers" and look for "youth" sizes. You could also try sewing your own!
 

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well, if you like FBs, they do make an XL... they also used to make an XXL and some retailers still have them instock.

also, toddler prefolds and sperate covers are always an option... the bummis SWW have an XL size that is huge, bumpy makes a super large (bigger than their XL), and then there's always knitted wool which can be custom made.
 

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Bumkins AIO, which I really like, makes a youth size for 42 pounds and up. And it's on clearance at this one store. I noticed it when I was searching around for Bumkins sales. Just scroll down until you find it:

http://www.tinytush.com/overstock_sales.htm

ETA: I've also found the fit of these to be quite adjustable. My daughter was able to wear her brother's XL Bumkins at 20 lbs, and those are supposed to fit 32-42 lbs. So although I don't have any direct experience with the youth size, it's possible you could use them sooner than 42 lbs.
 

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For What its worth my 37lb 42 inch DD wears Tiny tush one size diapers with liner at night were PT during the day so just gerbers and pull on covers for day time.
 
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