You don't need to use FOE on your covers if it irritates bub's legs. Try doing two layers of microfleece (or similar lightweight soft fabric) with a layer of PUL in between, turned and topstitched. It's just like making a nappy but without all the bulk (although use a nappy cover pattern with extra added around the edges to allow for seams and turning to make sure you get good coverage over the nappy). It makes a fantastic leakproof cover (we use ours for nights when DS's handknitted wollies are all in the wash), and if your bub is not a super wetter like mine, you may be able to get away without the PUL at all and just use fleece. We tried that though and he soaked through so I guess it depends on bubs. I did my fleece/PUL covers with side snaps and they have lasted AAAAAAGES! And nice and gentle - especially through the night while he sleeps.