There are so many mask tutorials out there. Why am I writing another one? I’ve made a few modifications for a better fit and got many requests for a detailed tutorial. This shaped mask leaves a small pocket of air under your nose and makes it easy to breathe and talk. The nose wire gives a good fit and does not fog up your glasses. The nose wire and the ties are removable and replaceable.
Are we not done with this pandemic? Do we need more masks? I don’t know. As I write this, businesses are opening up all over the world but most require some kind of mask covering the mouth, nose and most of the face. The masks may stay with us for a long time even after the worst is behind us. Most of the instructions will work for sewing by machine or by hand. I have mentioned in places where they may be different.
My husband, Srini, has fit-tested various versions of this pattern and, as with most spouses, given some valuable (and constructive) feedback.
Part 1: Making the mask template
My mask pattern is based on a pattern put by Joann fabrics. It is called the Denim Face Mask. Follow the link to their site for a video tutorial with detailed instructions. Download the pattern by clicking on Download PDF. Print the template and make sure the sizes are correct. Use the ruler at the bottom of the page to verify. You will also need some glue, scissors and a piece of cardboard. Use a cereal box or similar.
Glue the pattern to the cardboard. Draw a line 0.5″ from the right edge – red line in the image. I am making the template smaller because my modification I show later makes the mask a bit bigger. In the end, the final size is the same as the Joann Denim masks. Cut carefully along the boundaries and the red line. We will use this template repeatedly to cut out fabric.
Part 2: Making T-shirt ties
I initially used elastic for the masks but Srini said they are not comfortable. I found T-shirt ties are easy to make and also very soft and comfortable.
Find an adult size cotton T-shirt with minimal print and design. Lay it out on a flat surface, folded in half and remove the band at the bottom.
Cut as many 1.5″ strips as you can all the way up to the sleeves. You can use a ruler and a rotary cutter if you have them. Or you can use a ruler to draw the lines and a sharp pair of scissors to cut out the strips. You will need one strip per mask.
Each strip you cut is a kind of loop. Stretch the loop as far as you can and them cut them into two ties. This is an oddly satisfying step in the process.
From the sleeve area or elsewhere, cut out some 2″ X 5″ strips. These will be used to make a channel for the nose wire. Just a few will do. You need just one per mask.
Part 3: Cutting Fabric for the mask
Pick two fabric each about 12″ X 16″. Fold them right sides together with the wrong sides on the outside. One fabric is for outer and one for the lining. These instructions are for making two masks using the two fabrics. If you have any kind of fusible interfacing, iron it to one or both fabric. I ran out and can’t seem to find any locally or online at this time.
If you are using a rotary cutter, stack the two fabrics and make sure the edges match. If you are using scissors, you will have to repeat this step for each folded fabric. Using a washable marker, trace the outline of the mask pieces using the cardboard template you created in the first step. Also draw two lines 2″ apart to make a 2″ strip.
Cut out carefully along the drawn lines making sure all layers are cut correctly. You will be cutting enough for 2 masks. For each mask, you will have two pieces of each fabric. One piece will be a mirror image of the other. The 2″ strips will be used to make channels on either side through which you will thread the ties or elastic. I find this better than sewing them to the mask as in the Joann’s tutorial.
Part 4: Sewing the mask front and back
Cut the 2″ X 12″ strips you cut above in half to make two 2″ X 6″ of each fabric. Sew the ends of the 2″ X 6″ strips making a ring. This is how I chain piece several at a time.
Turn them right side out keeping the seam in the center. Fold them in half and press with your fingers. When you fold, all the raw edges will line up on one side. Keep them aside. You will need them again when we assemble.
Take each pair of mask pieces and make sure they are right sides facing. Sew along the curved edge. Go slowly if you are not used to sewing curves.
Before turning them right side out, make a few slits along the seam allowance up to the stitch line. This adds a bit of give and makes it easy to turn them out.
Turn each side of the mask right side out and sew from the front along the curve just next to the seam. This is called top stitching and gives a clean professional look. If you are stitching by hand, you can skip this step.
Part 4: Assembling the mask
For assembling the mask, you will need several pins or clips. Fold the 2″ T-shirt strip in half lengthwise and place it between the two mask pieces. Pin at the center making sure to catch the T-shirt strip and both mask pieces.
Similarly, use two more pins to hold the ends of the T-shirt strip in place.
Place the folded fabric strips between the two mask pieces on the sides with all the raw edges aligned and use a pin or clip to hold them in place.
Repeat on the other side. Also pin the two mask pieces at the bottom. This is what it looks like when everything is aligned and pinned. Now sew all around the edge leaving a 4″ gap at the bottom on one side. See the green line in the picture.
As you sew over the top, make sure you catch the nose wire channel. Also make sure you catch the edges of the side channels as you sew the sides.
Clip the corners taking care not to cut into the seam.
Turn the mask inside out from the 4″ gap in the seams. Use a chopstick or other blunt pointy tool to push out all the corners. Tug at the nose wire channel and the side channels to give the mask its shape. Press with your fingers all along the edges of the seam.
You can top-stitch all around the edges if you like. This will close the 4″ gap in the seams. If you are not top-stitching, you will have to stitch by hand to close the gap.
Sew the other end of the nose wire channel to the back of the mask to keep it in place. At this point, the mask is ready.
For the nose wire, I used some wire I found in the garage. I think that’s what we used for hanging pictures. You can use pipe cleaners or something similar. I cut about 8″ of wire and folded in half towards the center. I also used a bit of tape to cover the sharp ends of the wire.
Thread the T-shirt ties through the side channels using a safety pin.
I hope this was useful. Please leave a comment or send me an email if you have questions or comments. A video would probably be better but I don’t do well in front of the camera. Most importantly, stay healthy, stay safe and make wise decisions.
Thanks for sharing!
Thanks for sharing. I think that the face masks will be with us for a very long time so it is good that we keep trying to perfect them for comfort and for ease of construction.
Great tutorial. I modified the couple masks patterns I downloaded too, mostly eliminated a few steps.
Looks great. Most are so uncomfortable, but I think we may need them for sometime. I am marking this one as one to try next. I have a few tshirts that have bit the dust so I need to make up some strings….sounds like fun. Hope you and yours are well!
Hi Vasudha! Thanks for sharing your mask tutorial. I have hopefully made my last mask for a bit . . . but you just never know. I hope you are staying safe and healthy. Thanks so much for linking up this week. ~smile~ Roseanne
All right, I am convinced. I am going to cut up a t-shirt and try this pattern this weekend. Please stay safe and sane, my friend.