This article was taken from the February 2015 issue of WIRED magazine. Be the first to read WIRED's articles in print before they're posted online, and get your hands on loads of additional content by subscribing online.
Busy making in a workshop? You'll likely need a respirator.
Disposable face masks serve their purpose, but if you prefer reusable ones, they're usually plastic. These, according to leather-respirator maker Shaun Ferris, "have no grain, no personality". So, why not make one with its own unique properties?
Gather your materials Obtain leather with different thicknesses: 2.5mm for the body; 1.5mm for the straps; and 1mm for the edging and valve cover. You'll also need a 50mm-diameter can, a metal screen (speakers are a good source), a dust mask with a valve, two 50mm D-rings, two paperclips and some foam. Leatherworking tools are also needed, as are metal snips.
Construct the main body For the mask, cut a centre section and mirrored side sections out of the 2.5mm leather that will fit over your face when combined. Cut out a hole in each that's slightly smaller than the can you're using. Bend the shapes into place and stitch them together (they won't line up correctly until bent). Bend and test as you're sewing, or glue the pieces together first to test the fit. Dunk the assembly in water so it's more pliable and test on your face and correct accordingly.
Seal and add the valve Cut a 50mm strip of 1mm leather long enough to go over your mask's edges, glue it on, then glue the foam inside it.
Fold the foam inside the leather and sew on to the mask to create a seal. For the cover, use a 75mm square of 1mm leather. Soak it in water then stretch over the cylinder. Punch holes in the flat part, let it dry then glue to the respirator's central hole. Cut out the disposable respirator's valve and glue behind the cover.
Add inlet filters Open the can at the top and bottom and cut in half to make two small cylinders. Snip the jagged edges around the circumference to make several 6mm-wide strips. Push the can into the cheek hole, then hammer the strips flat and glue in place, retaining the can in the respirator like a grommet. Cut the metal mesh into circles just small enough to squeeze into the can but not come out the other side, then insert them from the formerly jagged end.
Strap it on and breathe Cut the respirator into a circle to fit over this mesh, then keep it in place with a paperclip attached to the can.
Attach D-rings to either side of the respirator with the 1mm leathers. Cut out the back 2.5mm leather section, leaving eight slots for the straps to loop through. Secure two straps to each D-ring by looping them through and sewing, then loop through the back piece, adjust for your head and secure by sewing.
This article was originally published by WIRED UK
