1. Cut an 8" by 12" long piece of fabric. This can be new or from used fabric such as an old t-shirt or pillowcase. Ensure the fabric will adhere to the Tenacious Tape. 

2. Fold the fabric in half. Use an iron to set the fold lines into the mask fabric.

3. Fold to make pleats as recommend in the illustration below. Alternate folding of pleat front and back [1"folds]. Pin pleats at the edges. You should have three pleats total. Remove pins mask assembly.

4. Optional: Iron to set the pleats in the fabric.

5. Next, cut three pieces of Tenacious Tape: two 1.5"x3" and one 8"x1.5" rectangles. If you do not have a ruler, use the squares on the repair tape backer to calculate the size (two 6x12 squares + one 32x6 squares).

6. Next cut two 32" [2.5ft] cords of the 325 Paracord.

7. Cut a 6" piece of flexible wire and fold in half or unravel a paper clip that will conform to your nose.

Assemble the Mask

Using Tenacious Tape to assemble a safety mask will be faster, however, the sew method will produce a more durable mask. Here are the instructions for both no-sew and sew method.

1. Take two 1.5"x3" on the left and right edges of the mask with 3/4" of the Tenacious Tape under the fabric. Release the bottom half of the backer paper and position the tape. Be careful not to touch the adhesive with your fingers.

2. Do not fold over the tape yet. Release the upper half of the backer paper and peel off. Repeat for both sides.

3. Next, place your 325 Paracord vertically on the adhesive at the edge of the fabric. Fold over the sticky side and press into fabric. If you prefer sewing, fold the fabric over 1/2 inch along the short sides and hand-stitch down, using the Sewing Kit.

4. Next assemble the 1.5" x 8" piece of Tenacious Tape at the open edge of the fabric. Use the same method as Step 9.

5. Install Gear Aid Ellipse toggles at the ends of top and bottom 325 Paracord pairs. Use a lighter to melt the ends of the paracord, so it doesn't unravel.

6. When finished, your mask should look like this.


Mask Care

Handwash your DIY mask in warm water with detergent. Clean gently for two minutes and avoid pulling at tape edges. Air dry. If the tape comes off from the fabric, remove the old and add fresh Tenacious Tape to ensure mask performance.


  • Test a small piece of Tenacious Tape on your DIY fabric to ensure for adhesive compatibility.
  • Tape down ends of the roll of t-tape to make it easier to cut, it wants to spool up.
  • Avoid Excessive soaking and very hot water when washing the mask.
  • Use hair ties or elastic head bands in place of paracord.