3D Bionicle Kakama Cloth Costume Mask + Pattern

Finished, five months after starting the initial drafting/ paper version, abandoning it a lot, and four test subjects later (sponsored by old jeans). Pattern made by tracing photos of the Kakama off of a monitor, lots of altering, and some initial regret for attempting it instead of a flatter mask.

It consists of an outer Kakama mask that snaps onto a 3-ply under-mask with nose wire and filter pocket.

Made this one in size L to hopefully accommodate most faces. Under-mask
can be sized up or down according to your preference (See extra “block” pattern pieces for all sizes. Just cut out the pattern along the labeled line with your desired size).

*The measurements are in US customary units.

*For personal/non-commercial use only, please.

*All of the seam allowances are ¼” unless otherwise stated. Pre-wash all fabrics on warm or cold, prior to cutting to prevent shrinkage. Preshrink your interfacing in hot water before use. Color-fasting may be necessary if the fabric dye “bleeds” when wet. Iron fabrics before cutting.

*Disclaimer: Mask has not been tested for effectiveness and does not replace personal protective equipment like medical or construction masks. This mask does not prevent, protect from, or reduce viruses or diseases.

Size guide for under-mask:

2XL is for extra large faces and loosely fits on the neck. It was designed to accommodate facial swelling. 2XL dimensions: Length across center: 11” Width/height: 6.75”.

XL is designed to fit males & females with larger builds. XL dimensions: H 6” W 8.5”.

L fits average males and females. L dimensions: H 5.25” W 9”. Model shown is wearing size L.

M fits average females, smaller males and teenagers. M dimensions: H 5” W 7.5”.

Care Instructions:

Hand wash cold, air dry. May be ironed after fully dry. Do not iron the straps.

Terms, stitches, and knots used.
Grain line: used to indicate that the pattern piece should be cut parallel to weft.

Seam line: Line on which fabric is stitched.

Notches: Small marks to align pieces accurately.

Baste: Temporary stitches that are later removed.

Buttonhole stitch.

Running stitch.

Lock stitch.

Backstitch.

Prick stitch.

Tailors knot, abbreviated TK in tutorial.

French knot.

Time needed: Varies, I took 18.5 hrs to cut and assemble mine.

Tools/Supplies needed:

Sewing machine.

Overlock machine/serger (Optional, zigzag stitching works too).

Iron and ironing board. Towels and old pillowcase (for fusing interfacing).

Press cloth (small piece of thin cotton fabric, laid over garment to prevent shine-marks during pressing).

Tailor’s ham or towels wadded into a ball shape.

Tailor’s clapper or a small, smooth block of wood.

Scissors and pinking shears/zigzag scissors.

Tracing wheel.

Pins and hand sewing needles.

Point turner or chopstick.

Disappearing ink fabric marker and white chalk.

Steam-a-Seam 1/4” tape roll.

Fabri-tac. Fray-check seam sealant.

Washable glue stick or Lapel Stick.

Two 6” long, ⅛” or ¼” wide elastic pieces for ear straps (Or stretch tube straps)

1-1.5 yards of 5/8” soft elastic in a color of your choice. I used cream/tan.

One nose wire.

I use soft, plastic coated wires that are similar to twist ties.

One metal, sew-on snap.

Thread: Polyester sewing machine thread in white, a color that matches your under-mask, and one to match your outer-mask.

6 strand embroidery floss in a color that accents your mask outer color.

1 strand white embroidery floss or basting thread.

Beeswax and paper towels for waxing your threads.

Ruler or seam gauge.

Fabric needed: For the Kakama outer-mask: 2 yards 100% cotton fabric in a color of your choice. This will be used for both the outer and lining. ⅛ yard of leather in accent color for the patch details. 2 yards ShirtTailor interfacing. For the under-mask: 1/4 yard 100% cotton in a color of your choice. I used a color similar to my skin tone. About ½ yard of white muslin for the lining and filter pocket.

Done!