Hi, that was a great idea to use a disposable to model your pattern from. Your tute was easy to read as you guided us through the steps. I wouldn't worry about the zig-zag stitch hurting the baby, it will soften up with frequent washing. The 'gusset' was the best part. I've made some cloth nappies for my little grandaughter to wear, but as she was a winter baby and they live in a tiny flat disposables were best because there is a limit to just how many indoor clothes frames you can put in a room as well as all the other baby stuff
. I'm also a great fan of serging the edges - it takes away all that extra work of 'turning rightside out etc.'. Serging also stands up to a lot of washing, I know because the original cloth nappies I made for my first child in 1981 lasted through three babies and beyond (I gave them away when I had no further use for them
Your post has generated heaps of great ideas and made some of us think now of other ways to do things and that's what craftster is all about.
Did you consider leaving an opening in the back for an insert like a 'pocket nappy' ? (at least I think that's what they are called).