This Air Flo is made from Ultrex. The type of material that Mother-Ease uses  is called Polyurethane Laminate.  Please refer to the home page for fabric sources.  The white side of this Ultrex is the coated side and the Jade side is the outside of the cover. I recommend using a soft stretch elastic.  I also recommend washing covers made with Ultrex and PUL by hand. PUL is more durable then Ultrex, however, washing by hand will only prolong the life of the laminate.

Here’s the Air Flo template I got from tracing the “real” thing.  This is the XL size, here are the dimensions.

(1)  16 1/2″  top of wing
(2)  19 1/4″  bottom of wing
(3)  12 1/2″  top of middle area
(4)    8 1/2″  bottom of middle area
(5)   13″       top of lower wing
(6)  11 1/4″  bottom of lower wing
5″        width of each wing
21 1/2″  length

I know it’s not the prettiest, but it’s the best I could do with what I have :).

Make marks on each wing.  1 1/2″ from the edge on the front wings. On the back wings make a mark 2 1/2″ at the top and 3 1/2 at the bottom of the wing. These marks are  where the elastic starts and where you will put the facing for your snaps.
Cut a piece of Ultrex for the facing as demonstrated here
Start the elastic close to the edge of the facing tacking it down with backward and  forward stitches, sewing the facing on at the same time. Continue to sew the elastic pulling it ever so slightly.  Ultrex gathers really well so if you pull too hard your legs will  be too tight.
When you get to the next facing, stop pulling the elastic and tack the elastic onto the  facing with a few forward and backward stitches
Here’s the cover with the elastic and the facings sewn on
For the binding on this cover I use “100% Nylon Tricot Stabilized Interfacing” It is found  at Hancock Fabrics in the Interfacing bin. If you want a softer binding you can use  regular Nylon Tricot, however it is almost impossible to work with. I get 3 yards of fabric and cut it into 2″ strips. 3 yards seems to be the prefect amount for an XL cover.
Start your binding on a corner of one of the wings.  You can cut the binding in 1″ strips and leave a raw edge, but I prefer to cut 2″ strips and fold the edges in. It looks neater.
This really isn’t hard to do.  As you sew, you have to stop a lot to keep the binding  folded and the cover in the middle of the folds.  This  is why the stabilized tricot is better than the stretchy slippery stuff.
When you get to the corners, lift the foot and pivot the cover.  You will have a fold in the  binding.
Make sure you pull the elastic straight while you sew the binding on.
When you get to the end, snip the beginning tail close to the edge.
Continue to sew the binding on sewing over the beginning binding leaving a tail of about an inch
Fold the tail to the inside of the cover.
And sew it down following the same stitching line on the binding. Cut the excess tail close to the stitches.
Here’s the leg hole with the binding sewn on.
Place 4 stud snaps in each corner of the wings on the front of the cover
On the back wings, place 2 socket snaps at the waist and 3 socket snaps at the legs.
The finished Air Flo copy!