PUL suggestion

[*Efjay*]

Yep Online is the only way I know of to buy PUL OR you can send your own material away to Wildchild & they have a PUL service where they will have your material laminated but I think thats about $19 a meter to do, but if you had something you really liked & wanted to make a nappy from then it would be worth it.
Your set up sounds good. If your using the towelling as your absorbant layer just do one piece that is the full pattern size then do a few layers as a rectangle booster to add to it (explained better on my blog) I think 3 or 4 layers would be good. Then you can make a lay in booster to add extra to your nappy once its done. So you could make a rectangle of say 4 more layers of towelling & top it with microfleece & then you have your lay in booster.

Now the nappy you cut open from Big W uses wadding its not absorbant at all. If you tipped a cup of water onto that it would go straight through. Don't worry about it for yours, not worth it.
Cheap alternatives for extra absorbancy are the microFIBRE cleaning clothes I mentioned earlier. You can usually buy a square of it from junk shops & you just fold into 3 & there you go, an extra booster for your nappy. But don't place it aghainst the babys skin, people say it drys out their skin. What I did was bought a heap & folded them into 3 then sewed on a layer of micrfleece & I use that as my booster on a lot of my nappies. Its good because it adds some fantastic absorbancy & by placing it ontop you get a faster drying nappy with good absorbancy. Once you have gotten the hang of things get your self some Bamboo or Hemp to use. But again only available online.

Where abouts are you?

eta - overlap??? Um unless your talking about having the wings so they overlap so you can close the nappy smaller? So if your using velcro to close you could have some ont he outside of one wing to you can close it tighter & it will have a place to join KWIM? Wildchild overlap, itti's are another that do, um I think BBB's do as well??