I have recently come to realise that most of my cloth nappies are irritating Bonnie's thighs! The nappies that don't are all pockets.. so I guess that's what I need to be making.

Does anyone have a pattern?

Some kids react to FOE
Fold
Over
Elastic
That's the stuff that looks a bit like bias binding, that is used to edge the leg holes and waist of PUL covers and and some PUL AIO's.

examples would be baby beehinds covers (PUL and wool).

You don't have to necessarily give up on covers if that is the issue.
Just use covers that DON"T use FOE e.g fleece covers.
Hand knit woollies have no leg elastic at all to irriate baby's thighs - great for long wears, like over night especially.
Fleece covers have hidden elastic.

You don't have to give up on AIO's either.
Just choose PUL AIO's that DON"T have the FOE (if that indeed is what is irritating your bub). I haven't seen any fleece AIO's that have FOE.

I have tried the weewaka side snapper pocket pattern on the Nappy network, i made the smaller size (supposedly from birth to 12 kg). My 10 kg bub is on the smallest snaps for that, so i think it's a generously sized pattern. The front wings go quite a way round her back, so i shortened them the 2nd time i made it.

so my message is, don't cut out HEAPS of some pattern you are trying for the first time. Cut ONE out, preferably out of material you won't mind if it's a dud, try it on your bub, IF it's a great fit and you're happy, THEN cut out a gazillion of them.