Here is the method and pattern that I used to make my own "Identity Preserving Balaclava." Hopefully other people will be able to use this to liberate their cold faces from social repression!
Step 1: Stuff you will need
-Photo Editing software (pretty much any program that you can crop images with)
-Inkjet Iron-on transfer paper (at least 6 pieces)
-Light-colored sweatshirt material (from a cut up sweatshirt or from a fabric store, 1/2 a yard is more than enough)
-A good pair of scissors
-Needle (or a sewing machine if you know what you're doing)
-A flat surface to iron on and a pillow case to lay on top of it
-A ruler or tape measure
Step 2: Take pictures of your head
Here are the angles that need to be photographed:
1. Face straight on
2. Left profile
3. Right profile
4. Back of the head straight on
5. Top of the head straight on
6. Neck and upper shoulders straight on
Step 3: Editing your images
Probably the best way to do this step is by trial and error. Take a ruler or tape measure and try to measure the dimensions of your head.
Crop your images to a ratio of 10 x 8 inches which will fit easily onto the 8.5 x 10 inch Inkjet iron-on transfer sheets.
Try to match the printed out images to the dimensions of your actual head, keeping in mind that they will probably need to be a little bigger than your head in order to fit over it.
You will probably want to print test images on scratch paper to make sure that the images are the right size before printing on the inkjet iron-on transfer sheets.
Remember to reverse all of your images before printing them onto the inkjet iron-on transfer sheets.
Step 4: Ironing on the images
note: it may help to wash the fabric after the iron-ons have been applied, I didn't do it because I was worried they might shrink a little and I had them measured to just the right sizes. You can try it though. I might work better because the iron-ons can be kind of tough to sew through and washing them is supposed to soften them up.
Step 5: Sewing the pattern together
Starting with the straight-on image of the face cut out the eye hole and the mouth hole and make sure they line up with your eyes and mouth. To do this cut a cross-shape and sew down the flaps.
Then line up the profile images with the straight-on image of the face. To make sure you get it right, first line up the jaw lines on either side, then use the straight pins to pin them together at the seams.
Stand in front of the mirror and try wrapping the pinned together pieces of fabric to make sure they accurately line up with the features of your face and head.
This process will probably take a lot of trial and error.
Try and line up the images of the face straight-on, the left profile, the right profile, and the back of the head, so that they make a straight line that can been eventually sewn into a tube.
Once those images are lined up and sewn together, cut the fabric with the image of the top of the head into thirds the long way. Then cut the middle third in half, like a hamburger. Line up the four pieces with the strip of images you have already sewn together so that the image of the top of the head is the same length as the rest of the strip. Make sure to line up the image of the hair from the top of the head with the hair from the other angles of the head (see picture).
Finally cut up and sew the image of the neck and shoulders onto the bottom of the images that you have already sewn together. This part will take a little more judgment calls than the rest because the main purpose of this is just to add enough fabric to the bottom of the strip of images so that later you will be able to make an even hem at the bottom of the balaclava.
Step 6: Fitting
Pin the pattern you have made into a tube and make sure it fits over your head properly.
Once you have the right fit, sew the seam that you have pinned together.
Go through the same process sewing together the seams of the fabric that cover the top of the head.
Once you have everything sewed up and fitting well enough you should be able to hem the bottom of the balaclava so that it is all even and none of the back side of the fabric is showing.
Finally, you can trim all the left-over fabric from the seams you've stitched together.
Step 7: Liberate your face!
But before you go out, don't forget to brush your teeth.