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5 from 2 votes

DIY PLAGUE DOCTOR COSTUME

This epic DIY Plague Doctor Costume is going to be a hit this Halloween!  It’s super easy to create an authentic plague doctor mask with this free printable pattern.
Active Time2 hours
Total Time2 hours
Yield: 1
Author: Heather Painchaud

Materials

  • Printable pattern
  • Large leather bag
  • Cardstock
  • Black Sharpie marker
  • Scissors
  • Tape
  • Pencil
  • White chalk pen
  • Hot glue gun
  • Hot glue sticks
  • Two small black jar lids
  • Black waxed cording
  • Leather needles
  • Long black jacket
  • Black balaclava
  • Leather black gloves
  • Wide brimmed hat
  • Cane or black staff

Instructions

  • Print the pattern onto 8.5 x 11″ paper.  Cut it out and tape it together to be sure that the fit is correct for your mask.
  • Use a white chalk pen to trace the pattern onto the leather.  Important: add 1/4″ to each piece of the pattern.  When tracing simply draw the line 1/4″ away from the edge of the pattern.  This gives us a salvage edge to wrap around our base and stitch together.
  • Cut out the mask pieces from the leather
  • Trace the pattern onto card stock using a pencil.
  • Cut the pattern out of card stock.
  • Trim the corners of each leather piece at an angle.  Basically you just cut off a tiny triangle so that the corners lay flat when glueing.
  • Use hot glue to wrap the edges of all of the leather pieces around all of the card stock pieces.  We originally tried doing this with double sided tape but found hot glue to be the better choice.
  • Sew all the pieces of the mask together to create the beak shape of the mask.  I used a basic stitch and laid each mask piece wrong sides facing before sewing them together.
  • Glue the eye pieces to the mask.  This can be tricky as the eye hole will bend and move.  Work slowly around the hole to glue the eye piece into place.
  • Stitch around each eye.  This edge is purely decorative, I did not stitch the eye to the mask as the layers of leather would be difficult to get through.
  • Using the straps of the bag make a strap for the mask.
  • Glue the straps into place using hot glue.
  • Add coordinating embellishments to the rest of the costume.  I used hot glue to glue pieces to the jacket and umbrella that we used as a staff.