DIY and crafting,  Masks,  Sewing

Gaiter style mask (Neck tube or scarf) with filter pocket made from a T-shirt

April 9, 2020 /

Since we all need to cover our mouth and nose during these days. One alternative is the gaiter style face mask. You can call it a neck tube, neck scarf, bandana, or sports band. It is basically a tube with stretchy fabric. By sewing a simple pocket, we can insert some filter and use it as a mask.

Don’t forget to watch the youtube video at the bottom of the article, and download the free pattern.

Choosing the material

We can make it out of an old T-shirt or knit fabric as long as it is stretchy enough to go over our face comfortable. To test the stretchiness, pull apart the fabric horizontally below the neckline (the area that will fit through the head). If it grows more than 15 – 20%, it is a good choice for a gaiter mask.

Most of the stretchy fabric has a percentage of the spandex. Knit fabric is more porous than woven. Wearing it alone is not strong enough to filter particles. But with the added filter, the mask can be effective for everyday use.

Advantage of the neck tube mask

  • It is easy to make. Just sew a tube and add a pocket. Sew in a wire (twisty tie) around the nose area is optional.
  • The knit (Jersey) fabric does not fray, so you don’t have to finish the edges.
  • Hand sewing is very doable since there are only a few straight lines.
  • Size is somewhat forgiving because it is very stretchy.
  • You don’t need extra material such as elastic.
  • It can be used as a neck scarf or headband when you don’t need the mask.
  • The knit fabric is more breathable and comfortable compared to woven.

Pattern

Download the free 1-page pdf pattern here.

The above pattern shows the finished size (8.5 x 14 inches for an adult). Seam allowance is not included. You can add 1/2 inch on both sides and leave the top/bottom unfinished.

You can cut 2 pieces and sew 2 seams, or cut 1 piece on fold (fold the fabric in half) and sew just 1 side seam.

The length is a personal preference. You don’t need it very long to use as a mask. If you want to wear it as a warm scarf, you can make it longer.

Pocket

Cut one piece of 7 x 4 inches (for adults) or 6 x 3.5 inches (for kids).

Adjust the pocket size depending on the filter size you intend to use.

Hand sewing vs. machine sewing

You can hand sew or machine sew this project. Many hand sewing needles have tiny holes and difficult to thread. Pick a good size needle with a slightly bigger hole for easier threading. There are hand sewing threads that are slightly thicker too. Use what you have if you have no choice.

A simple strong hand-sewing stitch is the backstitch. Sew one stitch back and 2 stitches forward. See the video at bottom of the blog. You can use a running stitch too. It sews up quickly but not as strong as backstitch.

For machine sewing, a straight stitch is fine for this project. You can also use a small zig-zag stitch or any stretchy stitch. Test it on the fabric first if you are not sure. A serger is great for sewing knits if you have one.

Steps

You can sew the side seams first, or the nose wire and filter pocket first.

  1. WIRE: The wire for the nose area is optional. Just fold down the center top fabric about 1/2 inch or 3/8 inch, place the wire (Twisty tie works fine, try to use a white one because other colors might run when you wash), and sew a line below the wire and on both sides of the wire.
  2. POCKET: Place the pocket below the wire and sew 1 horizontal line on top of the pocket, and 1 horizontal line near the bottom of the pocket. Now pocket is done.
  3. SEAM: Place the neck tube right side facing (the wrong side facing you), and sew the side seams leaving 1/2″ seam allowance.

Tip: Sew the side seam from the bottom up so you can try on halfway and adjust the seam allowance for a better fit.

That is it. Since the fabric will not fray. don’t worry about finishing raw edges.

Filter choice

Kitchen paper towel is a decent choice. You can also use double layers of facial tissue or a coffee filter.

I talked about using the AC filter or vacuum filter in the last mask sewing tutorial, but heard they might not be good for the human to breath through because of the fiberglass content. If you need to contact virus patients for a short time, the AC filter might be a good choice if no N95 mask is available. For everyday use, a simple paper towel might be safer.

Watch our video of the neck tube mask sewing tutorial

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