www.youtube.com/watch

(scale as needed.)

FTC,
I think like most of the comments above most of us used a template that is easily obtained as our pattern. I used a sleep mask and traced that to light card stock. I just trimmed that pattern down until I felt I had a good looking and functional pattern. The only surprise I found was that I had to cut higher on the bridge of the nose to get a good fit and block out all light. I agree with buster that a gap so the eyes aren't squished is key to comfort. I traced my patern to 2-4oz garment leather. For comfort I built an inner and outer shell and padded the two with synthetic batting used in quilting. That gave me a good looking all leather face piece that was soft and the batting helped to make it comfortable and block out light. The head band was 6 oz leather with a nickel plated 1/2" buckle. The buckle made it look sturdy, but I wouldn't use it again as you had to pre-fit it before you put the mask on or it catches hair when you try to tighten it up. Next time I would use velcro as the fitting mechanism. In the end I loved the look and feel of a soft leather mask, but don't use a buckle. Have fun; play nice.

Yours in Service,
Gabriel