How to Sew a Fleece Ski Mask

Last Updated: December 8, 2021

A ski mask, or balaclava, is a cloth head cover used to protect the face and head from harsh weather, cold, or wind. Although it can be worn a number of ways, it usually covers the majority of the head, leaving only the eyes exposed. Balaclavas are available at sports stores, ski outfitters and online. However, you can also sew a mask yourself. With a sewing machine, some fleece and a few measurements, you can create a snug, warm ski mask to protect you through the winter.

Method 1

Method 1 of 2:

Making a Ski Mask Pattern

1
Use a tape measure to measure the length and width of the ski mask wearer's head. Measure the width around the crown of the head (w1). Measure the length from the top of the wearer's head down to the front of their neck (h).
- Ski masks come in a number of different lengths. Decide if you want it to stop at the bottom of the chin or if you want it to pool at the bottom of the neck. Measure accordingly.
2
Measure the distance between the person's eyes (e). Extend the measurement to the outside of the eyebrows. It is essential that the space between the eyes be wide enough so that the wearer can see.

Advertisement
3
Measure from the crown of the head to the top of the eyes (w2). This will be important when you cut the hole for the eyes.
4
Add 1 inch (2.5 cm) to the height and width measurements to allow for seams.
5
Write down your measurements. You will need them later on in the process.
6
Buy ¹⁄₂ yard (0.5 m) of fleece. Although this amount will make more than 1 homemade balaclava, it will allow you to have some extra fabric in case of mistakes. Choose the thickness of the polar fleece based on the climate; the colder the climate, the thicker the fabric.
7
Trace a balaclava pattern on a piece of paper. In order to do this, keep in mind the shape of a balaclava and use the measurements you have recorded. Go to bikewinter.org/balaclava to see an example of a traced balaclava pattern.
- This pattern will be traced onto folded fabric, so the pattern should be only for the left hand side of the face. Divide the width measurement and eye measurement in half to get an accurate pattern.
- Measure and mark a line on the top of your sheet of paper to indicate the height measurement. Divide the width measurement in half and mark the horizontal width of the balaclava on your pattern.
- Measure and mark the length between the top of the head and the top of the eye sockets on the left hand side of your paper. Divide the eye width measurement in half and mark the measurement from the left hand side of your paper. You will cut out a space for the eyes using these measurements.
- Trace the pattern according to your marks and the shape in the example pattern. Connect your marks with a domed top for the head, a curve around the back of the skull, an indent for the neck and a space (for the eyes) that indents into the left side of the pattern. Make sure not to indent the area where your mouth and nose will go so that you have room to breathe.
8
Cut out your pattern with sharp scissors.

Method 2

Method 2 of 2:

Sewing your Ski Mask

1
Fold the fleece so that the fold is on the left hand, vertical side. The fabric should stretch horizontally, perpendicular to the fold. Try to fold the fleece so that it is the exact width of your pattern.
2
Folding the fleece, instead of cutting 2 sides, eliminates a seam down the front of the face.
3
Place your pattern on top of the folded fleece. Either draw around the pattern with a fabric pen or pin the pattern directly onto the fleece and cut with fabric scissors. The only part of the left hand fold that you will cut is the space for the eyes.
4
Turn the fleece inside out and fold again along the front. Sew on the inside of the fabric and then turn it inside out.
5
Pin the folded fabric together, the bottom and the eyes first before sewing the back seam together. Create a 3/4 inch folded hem in both areas.
- When you pin the eyes, make a diagonal cut in the corners and fold each side down. Pin it in place.
6
Ready your sewing machine with the type of thread you plan to use. Set it to a small zigzag stitch. This will give the polar fleece more stretch than a straight stitch.
7
Sew the bottom hem with a zigzag stitch. Sew the eyes with a zigzag stitch. You may choose to use a thread that is a matching color, especially around the eyes.
8
Pin the ends together at the back. Try for a 1/2 inch seam allowance. Polar fleece does not fray, so the seams are important simply to create the form of the hat.
9
Sew from the bottom of the ski mask at the back of the neck to the crown of the head with a zigzag stitch.
10
Turn the homemade balaclava inside out. Try it on to ensure it fits.

Community Q&A

Question

What is the (w2) measurement?

T. Chinsen

Top Answerer

The (w2) is at Step 3, the crown of the head at the top of the eyes; (w1) is the crown and represents the top of the eye opening, and (w2) is the bottom of the eye opening.
Question

Is it against the law to wear a ski mask in public?

Community Answer

It depends on where you live, but in general it's legal. Some people might think it's weird, and where I live you can't wear them (or any other item that covers your face) in banks and such. So check your local laws and consider the context/setting when you're wearing one.