How to make a Plastic Mesh Mask

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Step 5:

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Here you see the support wiring sewn into the mask, it's actually just some coat hangers, cut and bent to the shape of the mask. This will make the mask a lot more sturdier. I goofed a little on this one by putting the middle piece across the middle at about eye height, I should have had that go around the back... ah well, I'll get it right on the next mask..


Step 6:

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Now it's time to give the mask some character. As of lately I've gone totally to using mesh for making all the features on the mask, it's just a lot easier to cool than foam is, BBW v2 is very hot and the foam forehead and cheek pieces just add to it..

This is where you need to be a little creative with your bending and cutting of your mesh pieces. I liken it to origami, which is pretty close to what I do, using the mesh's natural stiffness against itself to create complex curves. Hold a piece in place, look at it for a while, try to get the feel for where you want it to all go.. Your measurements must be precise at this point or your face will end up crooked. When sewing on the opposing piece stop every now and again to make sure everything looks even..


Step 7:

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After adding the cheek pieces I usually start with the head straps and begin placing electronics such as fans and don't forget to put a small piece of foam at the bridge of the muzzle, the mesh will tear your nose up something awful if you don't!


Step 8:

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On masks like these it's been my practice to leave the bottoms of the cheek pieces open. This adds to the airflow to the inside of the mask, and allows you to conceal any hardware you want. In this case a blower fan for a v2 cooler, and on the other side I put in some elastic straps to hold the single 9.6v rechargeable battery pack used to power both fans. though not shown I also added all the other hardware at this point such as a switch to turn the fans on and off with, I also added a 3/4 amp fuse to protect everything from accidental shorts.



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Conceived and created by BigBadWolf
This page, it's images and the procedures contained herein are Copyright 1999 The Company of Wolves. All rights reserved.