Sunday, August 17, 2014

Aviator Goggles Mask

Created from cardstock, this replica of vintage flyer goggles
may be the perfect addition to a flyer's theme party
add a touch of authenticity to an airplane vignette,
or just make these to wear for the fun of it.
Sized in the file original for adults,
scale it smaller (recommended to no smaller than 70%)
for children. 
Embellished with eyelets, brads, and special 'D' ring hanger
(or use the similar paper shape included in the file)
for added interest,
with clear acetate/mylar "lenses" if desired.

1. Identify and cut the shapes: 
(top to bottom) side straps with tab reinforcement shapes, paper D ring brackets, main frame shape, frame end decor shapes, lens rim shapes, frame rings with clear acrylic lens shapes (invisible in this image because of the clear material)

2. Add some curl to the lenses body shape ends by applying pressure and drawing the paper card stock between finger and thumb.

3. Add some curl to the center "nose" ridge area to simulate real goggles or glasses.

4. Prepare the lens rim shape by folding the center rim edge back and gluing securely in place.

5. Prepare the outer edge of the lens rim shape by folding mini tabs outward as valley fold, second perforation line inward as mountain fold - do this for each of the 13 tab sections.

6. Identify the top tab of each shape by locating the tiny arrow cutout in the tab, as indicated by my pointing finger.

7. Locate and identify the top of each lens ring (right and left, that is) by retaining the waste shape that has the arrow symbol cut out. Keep trace of the tops by laying these shapes aside as they are cut in a specific identifiable way, or make a tiny mark on the backside of the shapes.

8. Fit the lens ring over the folded rim. Work the rim "bump" extension fully upward until each tab perforation rests snugly at the inner corresponding edge of the ring.

9. Apply glue to the tab upper surface, then press each section into place, pushing the tabs away from center for a snug final adhesion.

This is how the rim/ring assembly should look.

10. Prepare the clear lens shapes. For our model, heavy acetate is being used. My Silhouette cutting system does not cut completely through, but does give me a score line that I can cut with my craft scissors.

11. Position the corresponding shape behind the lens rim and attach in place. Our recommended adhesive for acetate sheet shapes is Kool Tak or Magic Tape.

12. Apply glue to the backside of rim lens ring ...

... then position over the front of the main goggle shape, line up the bracket end punch hole, center other edges so that an even margin is achieves between outer edges of frame and ring.

13. Position and attach the tab accent shapes at each end. NOTE that the shorter arm of this shape is positioned on top

14. If desired, add decorative eyelet through ring punch hole.

15. Prepare D rings by folding in half and gluing inner surfaces (for sturdiness).

16. Position at the tab end, then attach with a decorative eyelet.

NOTE: these can be glued in place, but will provide less movement of the back strap, which may prove undesirable for customizing fit.

For our model, I used a black decorative D ring purchased in the findings section of my favorate scrap book store. These may also be available (though perhaps not in black) in the picture hanging section of the larger home improvement centers.

My metal D ring was attached in place with a black eyelet.

17. Add some curl to the side straps.

18.  Position and glue in place the reinforcement tabs on each end, face side of both straps, matching the punch hole and edges. 

19. Slip the tab end through the D ring, then fold/loop back to line up punch hole end with strap hole. Glue end in place, then attach with a decorative eyelet, if desired (recommended).

20. Use cover circles to glue in place over each back (scratchy) side of eyelets.

21. Overlap strap ends at back, line up appropriate sizing holes, and attach a couple of brads to secure.

Here are the finished goggles.


  1. Just bought this at the Silhouette Online Store, so excited to put it together for my 2-year old son.

  2. Jodi, I just successfully assembled a pair of aviator goggles for my boys to wear! Thanks for your wonderful tutorial! I don't remember where I got the setting from, but to cut my clear acetate sheet, I used a speed of 1 and pressure of 24 with a double cut and it cut perfectly with the Cameo! Thanks for another fun design.

  3. Great cutting information. I will make a note and do this in the future!