How to Make a Protective Virus Mask with a Pocket

My reasons for writing this tutorial are two fold: 

1.  I only had a video to watch when I started, plus some measurements from a friend who had already made many masks. I do not work well from videos.  I want measurements. It took me almost a day to make my first mask with a pocket and nose piece.  The rest have gone a lot faster because I kept learning as I sewed.  Still, they do take time.

2.  I saw some masks at the Farmers Market that did not stay on the nose and/or had other problems that did not make them a very good defense against the Coronavirus.  

SUPPLIES for 1 mask.

FABRIC for 1 mask: washed, dried in a dryer, ironed before using. 

Outside 100% cotton fabric: Cut 1 piece 9” x 7.5”

Lining  100% cotton sheeting/pillowcase: Cut 1 piece 6.5” x 7.5”

Nose Piece: 4.5” up to 5” finished will work fine.

Using 18 or 20 gauge copper wire: 2 ways to finish ends so they do not poke the fabric.  You can use any wire of your choice as long as it will not rust.  

Option #1: BEND each end in a small loop. The length will depend on your bending. Experiment to see what works for you.

Option #2: Cut the wire. POUND the ends flat on a metal surface.  I used the side of a sledge hammer for my surface.

Using the 18 gauge, flat covered copper thermostat wire, CUT ~ 4.5”

Two strand thermostat wire on the left is copper inside.  The large roll makes it lay flat better than the small spool of 18 gauge copper picture hanging wire on the right.  The solid copper wire needs to have the ends either pounded flat or turned to prevent poking  the mask.  The thermostat wire is coated flat wire that does not need anything done to it after cutting.  I tested ironing it between 2 pieces of fabric.  It showed no melting after ironing the fabric flat.  I'm sure it could be made to melt.  But I also think the fabric might burn.  I'm not going to test this theory because I do not want to clean my iron.  Check what you have around your house.  You might have something that will not rust that you could use.  NOT rusting is a requirement.

Fasteners: If you are making masks for a particular place, check with them to see exactly what they would like. Elastic is usually required by hospitals and nursing homes because it is easy to use. Because of this Pandemic, elastic is in short supply. Some places have elastic, so they will insert the elastic into the masks when they are delivered.

Elastic type preferred: round, 1/8” flat, 1/4” flat, or make what you find work.  Larger elastic can be used to go around the head.  Some people are using large size pony tail holders. Problem = not adjustable.

Elastic length preferred: CUT 9” so that it can be adjusted to fit.

No Elastic: Use string, ribbon, anything that will tie. 
Loop design, CUT ~ 55" to 60”.

Construction Method:  Align the 7.5" edges of the outer fabric and lining, right sides together.
SEW a seam on each end ~ 1" to 1.25" in from the end.

[I have used 2 different fabrics for the outsides of my masks. I hope you are not confused by this. All of the linings are the same sheeting fabric from two sets of sheets.   I took photos continually, when I remembered.    Sometimes I missed a step.  When I have put the elastic in a pile of sewn masks laying on my table, as well as complete the prototype I'm working on today, I will have made my first 100.] 

PRESS seam open.  SEW a zig-zag or other type of finishing stitch along the edge of the lining fabric.  This will be the edge of the pocket to hold a filter if a person chooses.

Align the bottom edges.  Sew a seam the total length.  Press the seam toward the outer fabric. 

Turn right sides out.  Press the pocket edge to allow room for the nose wire.  
Press down over the bottom edge.  Now you are ready to make the nose wire pocket.

How to make a pocket for the nose wire.










Move needle as far to the right as it will go, start sewing the nose wire pocket.  

Sew in ~ 1" or more.  Stop.

Make a stop seam for the nose wire. 

Turn toward the folded edge.  Sew to that edge, back up to the sewn line, turn around to continue sewing until  ~1"  or more from the other edge.

Insert the nose wire until it hits the stop seam you just sewed.  Feel for the nose wire.  Make sure your needle is past the nose wire.  When you are absolutely sure the needle is past the nose wire, turn toward the folded edge.  
Sew up to the folded edge, then back down to the seam.  You have just completed a pocket to hold the nose wire in place.

Continue sewing the seam almost to the edge of the fabric.

Turn the fabric until you are heading toward the bottom.  Sew completely around the perimeter, catching the fabric pressed toward the bottom.  This will hold everything neatly in place. 

Your personal mask should not be used by anyone but you.  It must be washed after every wearing.  

How to pleat the mask with or without a template.

Lay the outer fabric down on an ironing board.
Fold down the top ~ 1"; press.

Bottom edge pressed up to almost meet the top edge.

Turn over with the outside up on the ironing board.  
Fold top fold down ~ 3/4".  Pin.

Fold bottom fold down so that is is  ~1" from bottom.  Pin in place.



The last step in pleating is to adjust the center pleat so that the total on each edge is ~3".  I used a metal ruler until I made this jig.

[I forgot to take a photo in process, but this is how it should look when pleating is finished.]

Now add cut 2" or cut up to 2 1/2" bindings on each side; leave the ends open for elastic or ribbon.  

Or you can add long, smaller bindings to use as ties.  These will need to be ~ 36" to 40" total length each side, with the 'pleated mask' inserted in the center.

PLEASE use lots of SOAP + Cover your nose and mouth

My view is that everyone should cover their nose and mouth when going into any contained space, ie grocery, pharmacy, feed store (animals need to eat too), etc where the people on the cash registers MUST WORK or risk loosing their employment.

Many of us that sew are making cotton, washable masks for hospitals, nursing homes, convenience stores, small markets and others in need of masks.  However, many people go without wearing anything.  Something is always better than nothing.

If you have a bandanna or a pillow case that can be cut into a piece big enough to act as a bandanna, please do so.

The Bandito 

The difference between the Bandito and a bandanna is only a simple dart in the nose area as well as making a knot in the free ends to get it closer to the body.  This makes it cling to the face better that just using a bandanna.  The tuck can be made my hand sewing, stapling, or other means of your invention.  Maybe duct tape might work? If you can not alter the bandanna, just use as the bandits did, tie it in back without a dart. 

The main idea is to get it as close to your face as possible + stop the flow of air and especially droplet leaving your mouth and nose.  The knotted part hanging could be stuffed in a shirt or coat to decrease the air flow even more.  Using a pillow case will increase the density of the material which will trap more particles.  NO, this will not stop the virus.  It will help.  It will also help you from touching your face which is very important.

The BEST thing you can do is stay in your home.  Only go out for absolutely necessary items such as medicine and food for you, family members, pets and others who can't get out.

Your eyes are also vulnerable to infection from this virus.  Wear glasses or sunglasses to protect your eyes.

https://www.ecowatch.com/coronavirus-face-masks-2645078070.html

"All masks and goggles are of little use if the most important hygienic principles are neglected. For example, if you come home after a long bus or train ride, where you touched handrails and handles, take off the mask and scratch your nose, You could have left out the protective mask just as well."

When you come home from being in a confined space, slip off your shoes and leave them at the entrance.  Take off your mask. 
Alternative #1.  Drop the mask on the hard floor or a container.  Leave it alone for 4 or more days.  The virus will die within the 4 days.  WASH your hands.  Wash the sink handles, the door handle and anything else you touched.

Alternative #2. In your stocking feet, walk to the bathroom sink without touching any handles, take your mask off, drop it in the sink.  WASH your hands.  Now wash is mask with LOTS of soap and water.  Hang it to dry, or put it in the dryer, or iron it dry. Wash the sink handles, the door handle and anything else you touched.

Proper Hand Hygiene:

SOAP up, make lots of lather, WASH vigorously for 30-60 seconds.

Please remember that I am not a scientist.  My information is gathered from the best sources I could find.  One other important thing is NOT to touch your face, especially your eyes.