Re: Double gussets - just an illusion?!
Yeah, all the "double gusset" diapers seem to actually do is create a deeper area for a thick insert/diaper. It works well if you are trifolding prefolds or trying to fit a cover over a bulky fitted. But it doesn't actually give double the protection for us.
They never worked on my kids since they all have had very chunky thighs. I really don't care for covers with the double gusset added. They seem bulkier, stiffer and less forgiving on chubby baby thighs.
SAHM to DD