Here’s a list of materials you will need for making masks using my modified Jesse Killion pattern. There are actually three lists: what you need to make the sample shells, what you need to make the masks, and tools you will need.

You can watch the 37-minute tutorial video here:

Note that the video shows how to make a two-layer cloth face mask. It does not have a filter pocket or inner filter layer! I would rather have a tight-fitting mask that doesn’t leak than one with a filter that leaks around the edges.

It is possible to put a permanent inside layer of chiffon in this pattern. I’ll post another video about that sometime.

To make the sample shells, you will need:

• 8 yards unbleached muslin.
  Zig-zag stitch the edges. Wash the fabric in hot water and dry it on hot. Iron the fabric before using it.
• 3 packages of Wright’s 1/2-inch single-fold bias tape
• 30 14″ long, 3/8-inch wide cable ties (zip ties)
• 100-foot roll of plastic-coated garden wire

To make masks, you will need:

• Cotton fabric
  I use a fairly lightweight quilting fabric, probably around 220 thread count. I can get 2-1/2 masks from 1/2-yard of a 44″-wide bolt. I’ve used 600-thread count sheet material, but find it’s too hard to breath through, even with just one layer.
• 14″ long, 3/8-inch wide cable ties (zip ties)
• 1/2-inch single fold bias tape
• Thread to match
  I like Guterman 100% polyester thread, but you know your machine best.
• Fray Check to seal the interior seam edges

For the nose wires you will need:

• 14-gauge copper wire
• Don McCunn’s pattern for bending nose wires, from his Custom Face Mask e-Book with Patterns (check out Don’s Custom Face Masks page for more great ideas, too)
• 1000-grit sandpaper

For the ties to secure the mask, you will need:

• Single hole bubble cord locks and
• 650 coreless paracord OR
• Stretch jersey knit (around 44″ of either)

If you put in a filter layer of chiffon, you will need either:

• Chiffon
• Stretch chiffon

Tools you will need:

• Clover clips
  I have about 30 of these. You really need to use clips rather than pins, so you don’t puncture the front of the mask.
• Needle nose pliers for cutting cable ties and wires
• Butane lighter for melting the sharp edges off cut cable ties

I know it’s dangerous to talk about favorite scissors, but I use:

• Fiskars 9-inch scissors
• Fiskars 5-inch scissors

It’s not strictly necessary, but my ironing board is happier with a:

• Silicone iron rest