How to make a Robin/Zorro black mask from cotton?

[melstapler]

Has anyone attempted to make a black mask or mask of any color using cotton t-shirt fabric? I chose 100% cotton because it can be pre-washed without fading and shouldn't leave any markings on the figure's face like you would see from a mask made of other materials. Also, I like the flexibility of cotton and how it can stretch. Any personal stories, opinions, instructions or patterns/recipes you might have would be of a great help.

[PNGwynne]

I don't want to shoot you down, because anything's possible. But IMO you're going to have trouble with/be disappointed in using cotton for a mask. It's too thick and will fray unless you seal the edges. And the sealant is potentially more dangerous to the head than dye.

I'd use black vinyl from a binder (pretty inert) or softer upholstery vinyl, which is usually backed with a fabric batting.

The other option might be to try wide flocked ribbon. Try to find the synthetic, non-woven versions.

[ZMOQ]

Not cotton T-shirt material. When you cut it, the edges fray. A better option is to buy cotton broadcloth (known as Kona cotton) from a fabric store. Soak it in matte Mod-Podge and then place it over the figure's head while wet. Press the fabric into the eye sockets and bend it around the nose bridge. Let it mostly dry. Then peel it off the figure's head and trim it and punch out the eyeholes. The Mod-Podge seals the edges and stiffens the fabric and can hold a shape when dry.

I'd avoid the use of any plastics or vinyls. PNGwynne- I have doubts about vinyl binders. I've seen it many times where papers printed on a laser printer or a photocopy machine stick to the vinyl binder cover. Vinyl has a bad reaction with toner, and I wouldn't trust it with painted PVC heads.