Re: Double gussets - just an illusion?!
I think the only function of a gusset around the leg on a diaper cover is its ability to "snug up" against the thigh better than the outer elastic. This is why they tend to be too tight for chubby babies.
A double gusset with two real layers of protection would be like a rumparooz pocket.
Maria, wife to David and stay-at-home-mama to four children.