design
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choosing glass and lead
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full scale pattern
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cutting glass
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fabricating window
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cementing window
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final cleaning of window
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A R T I S T I C E N D E A V O R S
Custom Stained and Leaded Glass
Process
First the design is drawn full scale. Every piece of glass is hand cut and labeled for position on the pattern. Next the window is fabricated. There are two basic ways to fabricate a stained glass panel, one uses the copper foil method and the other uses lead came.
Copper Foil Method
Each piece of glass is hand ground to remove any flairs or unwanted edges. Once ground, each piece is prepared to receive the copper foil. Foil is wrapped around each piece then rolled to ensure proper adhesion. Each piece is laid out on the pattern and carefully aligned. Solder is then melted which adheres to the copper foil and not to the glass. The panel is cleaned, patina, waxed and cleaned again. I let panels sit for 24 hrs. then clean them one last time to remove any residue cleaning products.*
Lead Came Method
Again a full scale drawing is made and each piece of glass is hand cut. Once all of the glass is cut, they are laid out upon the pattern and fabricated by placing lead came between two adjacent pieces of glass. If the fit is satisfactory the joints where two pieces of lead meet are soldered together. Once each piece of glass has been soldered into place the panel is flipped over and all of the lead joints are soldered again. Upon completion of the fabrication process, the leaded panel must be cemented. We use a traditional cement which is applied between the lead and the glass on both sides. As the cement dries we must remove the excess numerous times over a 3 to 5 day period. In about 1 week the cement should be dry, the panel is then patina and waxed, cleaning each and every piece of glass on both sides.*
* These processes have been simplified and generalized for informational purposes only and are not intended to be step by step directions for fabricating stained glass panels. The fabrication of stained glass panels, when done correctly, is an exacting and time consuming process. From design to finished product, both form and function are carefully considered and kept in mind throughout the whole process.
Below is a step by step visual display.
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