The pattern and instructions can be found here.
Wash the fabric in hot water, dry and iron smooth. If you have yardage, you can fold it in half longitudinally and then again longitudinally so that you have four layers. Be sure that the folds are parallel and crisp.
The easiest way to cut the fabric is using a rotary-cutting equipment: mat, ruler and rotary cutter. If you don't have these, you can make a paper pattern, pin it on the fabric and cut the mask pieces out.
Cut:
2 strips 1 1/2" wide from selvedge to selvedge or at least 36-38" long, which will be trimmed to length later. (I like to cut 4 strips, because when you cut through the four layers, you will have enough of the main mask pieces to make two masks.)
For each mask, you will need 2 rectangles 8 3/4" X 7 1/2". (When you cut through the four layers, you will have 4 rectangles, so enough for 2 masks.)
Press each 1 1/2" strip in half longitudinally. Then press each raw edge of the length in to the middle of the strip. Finally, press the whole piece with the two edges tucked in. It will look like folded bias tape. These will be the ties.
Note: Using the diagram/pattern on the second page of the instructions, the lines are called "Step 1(B) through 2(D)," so we will call each line by those names.
Take one of the 8 3/4" X 7 1/2" rectangles and, with the right side of the fabric up, draw a line 1/2" in along the narrower edge of the rectangle using a fabric marking pencil. This will be the bottom of the mask, Step 1(B). Draw the line 1/4" from the bottom raw edge, Step 1(A).
Then go up to 2 1/4" from the same edge and draw another line, Step 2(D).
Turn the rectangle around and measure 3 1/2" from the opposite edge, still on the right side, Step 2(B). (This will be the top of the mask.)
Now turn the rectangle over as if you were turning a page in a book. On the wrong side of the fabric, draw a line 2 1/2" down from the top, Step 2(A).
Rotate the fabric again and still on the wrong side of the fabric, draw a line 3 1/4" from the bottom raw edge, Step 2(C).
Repeat for the second rectangle.
Now to press the folds:
Fold on each line on the right side and press each one thoroughly.
Turn the piece over and do the same with each line on the wrong side. Turn up the bottom raw edge to meet the first line marked and press. Then fold it again on the line and press again.
Do the same with the second rectangle. These will be the bottom hems.
On the right side of fabric and holding the hem closed, stitch 1/8" to a scant 1/4" from the folded bottom edge of each rectangle. (You can chain these together to save time.)
Pin the folds closed, making adjustments as needed to be sure that each side of the mask will measure 4 1/4".
Sew each edge to hold the folds closed using a 1/4" seam. Press.
Pin the rectangles together, right sides together and top raw edges lined up. Sew the two pieces together using a 1/4" seam. On the right side, press the seam to one side.
Fold the mask with this seam up and the wrong sides together. Mark the wire nose piece slit according to the pattern along the top seam edge, beginning and ending 1 3/4" in from each side and 1/2" deep, leaving 3/4" open for the wire to be inserted. (I like to start at the far left, sew the vertical stitches, backstitching at the beginning, pivoting at the corner and sewing to the mark for the opening, backstitching, then lifting the presser foot and moving to the base of the right-hand end of the slot, inserting the needle again and sewing the other vertical stitches, backstitching at the beginning and end.
Attaching the ties:
Find the middle of each tie. Open the folds and place the middle of the tie open against the center of the side of the mask that has the pleats, matching raw edges. Pin in place.
Sew from the top of the mask to the bottom along the raw edges with a 1/4" seam, backstitching at the beginning and the end.
Fold the part of the tie that attaches to the mask around the raw edges and pin in place. Beginning at one end of the tie, sew the tie closed, sewing over the side of the mask.
Repeat for the other side. Press.
If this is going to a hospital, they will insert the metal wire for the nose and a filter in the opening at the bottom. If you're making this for yourself or a family member, you can insert a pipe cleaner or other flexible metal wire for the nose. You can make your own filter using two layers of cotton flannel, 6 1/2" X 3", sewing them together and finishing the edges with zigzag.
Keep in mind that this mask may provide some protection to the person wearing it and probably more to people in the vicinity. It is not a medical-grade mask and should not be relied upon for complete protection. Use it if you are sick to protect your family members. Use it if you must go out, but be careful what you touch and be sure to wash your hands thoroughly when you come home, as well as wiping down anything you bring home with you using a disinfectant or alcohol. If you don't absolutely have to go out, stay home. You can make more masks.
Note: I will be updating this blog post as I get more photos or have more experience with the pattern or comments indicate something needs rewording. Thanks for your patience.
Credit: St. Charles Health System
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