COMPLEX MASK INSTRUCTIONS

A printable PDF file of these instructions and the pattern can be found HERE.

MATERIALS

Fabric
Fabric must be light colored, tightly woven, cotton blend, and pre-washed. Patterns are fine. The type used by quilters is ideal. Most of our volunteers have their own stash. 

  • 9" x 15" fabric outer layer

  • 9" x 15" fabric lining layer per mask
    (3 masks can be made from 1/4 yard i.e. 9" of 45” wide fabric)

Elastic
Each mask requires 22" of clean elastic. It can be round or flat. 1/8 - 1/4" diameter – maybe the elastic off an old fitted sheet (just make sure it still has some spring in it).

Elastic ALTERNATIVE - Since hundreds of people are now sewing masks, many of the stores are cleaned out of elastic. If you can't get elastic, you can use a sturdy ribbon. Cotton or a cotton blend, not synthetic which won't launder well. It should be light colored. You can make your own ribbon ties out of the same fabric as the masks if you want. They need to be

  • 22" of elastic or sturdy 1/4”-wide ribbon needed per mask

Wire
Each complex mask has a 3" piece of wire for the nose crimp. This wire should be no smaller than 20 gauge, or bigger than 12 gauge. It should be something that can be washed and not rust. Thinner wire can be doubled. Decorative wires, floral wire, picture wire have all been used. Pipe cleaners/chenille stems are allowed but ONLY if you don't have anything else. Please don't use paper clips or twisty ties. Test the cut ends and make sure they are not sharp. You can cut the wire a little longer and curl the ends into small loops to tuck in any sharp ends.

·      3” per mask (extra if needing to curl ends)

Tools
Sewing machine, thread, scissors, ruler, marker, iron

Filters
If we have provided you with filter material, please cut and place on inside of the mask. Otherwise leave one side open for inserting a filter at a later date.

PATTERN & CUTTING

1. Print out paper pattern pieces at actual size on 8.5” x 11” paper. Use the mini ruler to adjust size as needed. Cut out the A and B paper pattern pieces. The PDF of the pattern to print can be found HERE.

We are using two different fabrics in the photos, one for outer layer, one for lining layer. This is recommended but not required. It's okay to use the same on both layers.

Fold your fabrics right sides together.  Pin pattern pieces to folded fabrics and cut two A  (outer) from one and two B (lining) from the other. Transfer the 2 dots from pattern piece A to wrong side of outer layer fabric.

ASSEMBLE
2. Sew center curves of outer layers, right sides together with a 1/4" seam allowance. Sew center curves of lining layers, right sides together with a 1/4" seam allowance. Clip the curved seams at about 3/4” intervals but not down to the seam.
3. Fold straight sides of lining fabric over 3/8", wrong sides in. Press, then finish the edge by sewing fold down.
4. Pin the two layers together, right sides facing in, curves tucked into each other snugly, center seams and top and bottom edges lined up.
5. Sew 1/4" seam across top and bottom edges of layers. Clip the curved seam around the nose.
6. Turn mask right side out. Press. The pointy end of an ironing board works well for this. Fold over 1/4" of the top and bottom of the wings of the mask, so they line up. Press flat and straight with the iron.
7. Sew a seam 1/8" from the edge, across the whole top of mask -  start at one end of the wing, sew down folded edge and across the top of mask (top stitching) and down the other wing fold to the end. Do the same for the bottom edge.

FINISHING
8. Make the sleeves for the elastic by folding the raw ends of the wings down 1/4" and pressing with iron, then folding again toward the center to where the dots are, pressing and sewing them down,  top to bottom. The hemmed edge of the inner layer and the folded over sleeve abut. Don't sew the pocket closed.
9. Lay the 3" cut wire against the top of the mask where the channel will go and mark 1/4" longer on each end with a pin. Sew a line following the curve of the top of the mask, 1/4" down from the top stitching. The channel should be 3.5" long. Close one end of channel by making a 90 degree left turn and sewing up and off the mask.
10. Insert the wire into the channel through one of the pocket openings. Push the wire to the closed end so you have room to sew up the open end. Sew the channel closed with a short seam.
11. Cut the elastic into 11" lengths and thread through the sleeves. Tie each piece into loop with a loose knot.

PACKAGING THE MASKS
Put sets into cloth or plastic bags and label the number of masks included. Drop off at a collection site or contact us to arrange pick up.

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