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Mushy the Mushroom

3-Ply Cloth Vahi Face Mask + Sewing Pattern and Tutorial to Make Your Own

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A challenge seemed enticing, so I designed this sewing pattern for a Vahi face mask. The pattern was created by tracing the outline of a scaled Vahi mask off a monitor, onto a piece of paper. Then the outline was cut and splayed to the angle of a fitted face mask and seam allowances were added. 

schmallvahidraft.jpg.2ac6d30d603d00cbfc0cc45544f1df1a.jpg

Here is the finished mask. It’s 3-ply, has a nose wire casing and includes a filter pocket. It’s made in XL size, because that seems to be the most common size people request.

 

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(Sorry for the frightening facial blurring.)

 

You can make one too, if you would like! The photo tutorial and pattern are below. It is a preliminary hand-drawn pattern, so lines are a bit rough. The steps also could be streamlined further if one had more fabric, but this one was designed from scraps.

The measurements are in US customary units. The pattern is for an XL size mask, but I have included my “Master block pattern” that has all of the additional sizes listed. You would need to re-scale the Vahi mask parts page in your printer settings for the smaller sizes. Cut out the pattern along the labeled line with your desired size.

*It is for personal/non-commercial use only.

*Disclaimer: This mask design has not been tested for effectiveness and does not replace personal protective equipment like medical or construction masks. This mask does not prevent, protect from, or reduce viruses or diseases.

 

Notes:

All of the seam allowances are ¼” unless otherwise stated. Pre-wash all cotton fabrics on warm or cold, prior to cutting to prevent shrinkage. Color-fasting may be necessary if the fabric dye “bleeds” when wet. Iron cotton fabrics before cutting.

This may not be the best pattern for beginners. It took five hours to cut, sew and assemble the mask after the initial pattern drafting. This is a markedly longer time period for mask construction, so don’t be discouraged if it takes a while to complete. :happy:

Size guide:

2XL is for extra large faces and loosely fits on the neck. It was designed to accommodate facial swelling. 2XL mask dimensions are as follows: Length across center: 11” Width/height: 6.75”.

XL is designed to fit males & females with larger builds. XL dimensions are as follows: H 6” W 8.5”. Model shown is wearing size XL.

L fits average/larger medium males and females. L dimensions are as follows: H 5.25” W 9”.

M fits average females, males and teenagers. M dimensions are as follows: H 5” W 7.5”.

Care Instructions:

Wash before wearing. Hand wash cold, air dry. May be carefully ironed after fully dry. Do not iron the leather patch details or elastic straps, as they may melt.

 

 

Tools/Supplies needed:

Sewing machine

Overlock machine/serger (optional, zigzag stitching may be used)

Scissors 

Tracing wheel

Pins and a hand sewing needle

Toothpicks (optional)

Ironing ham, mini ironing ham, or towels wadded into a ball shape.

Disappearing ink fabric marker

Fabri-tac or similar fabric glue

Washable glue stick or Lapel Stick

⅛” or ¼” wide elastic, preferably in black.

One nose wire. I use soft, plastic coated wires that are similar to twist ties.

Black, orange and white polyester sewing machine thread

Fabric needed (generous estimations to allow for miscuts):

About ½ yard of very dark gray cotton fabric for mask outer

About ½ yard of orange cotton fabric for Vahi mask details

About ½ yard of white muslin for the lining and filter pocket

⅛ to ¼ yard of black faux leather, or very thin real leather for the oval patch details

 

 

3 Page pattern:

Page1

Page2

Page3

 

Kind of messy photo tutorial:

(I have linked to the photos, so as not to overwhelm the website. I unfortunately do not know how to directly link to them. Here is the Complete Album , in case that's easier.) 

Step1

Step2

Step3

Step4

Step5

 

Step6

Step7

Step8

Step9

Step10

 

Step11

Step12

Step13

Step14

Step15

 

Step16

Step17

Step18

Step19

Step20

 

Step21

Step22

Step23

Step24

 

I hope these steps make sense, this wasn't really a planned thing...and I have zero training or qualifications to make tutorials. Best wishes and hope you have fun if you decide to make one! :happy:

 

Edited by Mushy the Mushroom
Added washing instructions + dimension info.
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On 8/31/2020 at 9:37 PM, Unreliable Narrator said:

nice!

 

On 8/31/2020 at 9:40 PM, Daler99 said:

This is awesome!  Great work! :D

 

On 9/3/2020 at 7:52 PM, Toa_Kralich said:

Wicked cool! Great stuff to encourage responsible mask wearing :)

Thank you all! :spinsmile:

 

I really should have made a "test subject" version before making the real one, though....The top corners are a tad too pointy due to sewing error & I should have ironed this one more... Oh well..there's always next time. :happy:

Might eventually try to make a full-face mask pattern...If it's possible...

Edited by Mushy the Mushroom

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Were you planning any other mask designs like this? You might also do well with an Etsy, if sewing up a few more of these sounded appealing! :)

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@Toa_Kralich Maybe when I have time, I really want to attempt a full face mask, instead of just a lower half one. Not sure how complex that will be...Sounds alluring to try! :happy: I've actually had an Etsy for a couple years now, I'm just concerned that selling LEGO themed items would violate intellectual property laws. (I hope mentioning this is allowed, sorry if not.)

Edited by Mushy the Mushroom

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A lot of people sell Bionicle-themed stuff on etsy and such - custom masks, moulds of existing masks but with different plastic colourations to what we got, painted masks, etc. I think a hand-made hand-sewn face mask would probably get along alright as a result? :P

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On 9/6/2020 at 6:03 AM, Toa_Kralich said:

A lot of people sell Bionicle-themed stuff on etsy and such - custom masks, moulds of existing masks but with different plastic colourations to what we got, painted masks, etc. I think a hand-made hand-sewn face mask would probably get along alright as a result? :P

Yeah, a lot of themed merchandise is there, but infringing shops are flagged and shut down fairly quickly if they continue. I think the only way to legally sell such items would be to obtain permission/a license from the intellectual property rights owner. I've experienced intellectual property theft from a company in the past, and really wouldn't want to commit it myself... I'll just stick with sharing patterns and tutorials for these. :)

Edited by Mushy the Mushroom

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This is amazing! Love it! :)

Something else that might also be cool further down the line would be to make face shields with different Kanohi designs printed on them!

Edited by Liopleurodon
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@Master Inika @Aderia  @Liopleurodon

Thank you all, you're so kind! ^_^

Also, thanks so much BZPower, for the "feature"...Quite astounded!

On 9/11/2020 at 6:06 PM, Liopleurodon said:

Something else that might also be cool further down the line would be to make face shields with different Kanohi designs printed on them!

@Liopleurodon What a brilliant idea! I wonder if this could be done with decal stickers as well.

 

Edited by Mushy the Mushroom
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