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Step-by-step photo's of the current project being made in our studio (and comments from the artist):this page was
updated 12/05/2006 09:41 AM
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Glass Eye 2000 software was used to create & adjust this custom design & patterns to size. |
2. full-size copy & cartoon  Trace one copy onto freezer paper
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Print/make 3
copies (one is transferred to wax paper to use for the glass). I print out a miniature version to refer to for glass
information,
grain direction and
assembly. (this is called a "cartoon".)
One full-size copy is used on the layout board, and the other is used to cut apart for pattern pieces on glass and the third is to refer to and keep as an original. |
 3. Number & Grain Direction |
Number every piece and indicate grain direction. |
 4. Cut apart pattern |
Special foil shears are used to leave exact spacing between the pieces for
the foil width.
It seems like this takes forever to get done - after this it starts coming together quickly. For a glass artist, the prep is always the longest - I guess we just can't wait to get to cutting! |
 5. Select Glass & tape pieces down |
Selecting the glass is one of the most difficult and
most rewarding. There are literally thousands of different glass
styles and colors available - each with it's own characteristics.
Mary choose colors that will compliment the decor. We literally matched the colors in a pillow she supplied for us. The whole aesthetics of the glass piece is controlled by the glass selected. Sometimes it takes hours to find just the right pieces. |
 6. Cut Glass |
Using a glass cutter (I prefer my nifty Cutter mate), cut along the pattern following the pattern as close as possible. I Later, I will perfect each piece with the grinder. |
 7. Grind to match pattern |
After each piece is cut, I clean them up and get them to the exact size with my grinder. Notice that I still have the pattern taped to each piece; this will guide me as to what glass needs removed during grinding. |
 
 
 
 8. Assembly |
Each piece is articulately cut, ground, and placed onto the layout - leaving approximately 1/32nd of an inch of tolerance between the pieces. In other words, each piece has to be cut and ground to almost perfection. Because these panels are going into windows, they must be sized to perfect dimensions. Whether they get framed or go into a window, I feel having them square is VERY important. (Beware...some artists aren't so concerning.) You should leave 1/8" all the way around. |
 
 9. Foil all the pieces |
Every individual piece is wrapped in 7/32" foil. Since the background glass is clear and the finished product will be silver, I used a special foil tape that is silver on the back. If regular copper foil was used, the copper would be seen through the glass. |
10. Flux |
When the panel is ready to be soldered together, flux is applied to all the foil. This causes a chemical reaction on the copper so that solder will adhere to it. |
11. Solder |
With a very hot soldering iron, all the pieces are tacked together at the
joints with solder.
After all the joints are tack soldered together, I apply a 50/50 solder along the foil seams. After that is completed, I go back over it with 60/40 solder and carefully build up a nice smooth bead of solder. This is very time consuming. This panel took over 8 hours to solder both sides. |
12. Clean & Wax |
After all the soldering is complete, clean well with soap & water, baking soda, or window cleaner to remove the excess flux. Apply a good wax containing carnauba wax will keep the solder lines from oxidizing. |
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(Optional) 13. Apply patina |
This step is optional. |
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14. Clean, |
The final step is cleaning and polishing. GOOD 'OLE ELBOW GREASE! Clean with soap & water and alcohol with a soft cloth to remove extra patina. Apply a stained glass wax or a good car wax that contains carnauba oil. This will reduce chemical reactions and chalky buildup that happens when pieces don't get cleaned well enough or is exposed to pollutants. |
For a custom designed piece, send us an e-mail, fax, or snail mail it with the desired design and desired colors. Refer to each glass manufacturer for a sample listing of colors available. We will then quote you a price for your custom designed glass piece. We will make every effort possible to match your desired color choices.
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Send mail to webmaster@GlasswithaMission.com with questions or comments about this web site. Copyright © 2002-2008 Glass with a Mission. Prices listed and availability are subject to change. Glass with a Mission 1-866-263-9319 Lake of the Ozarks - Sunrise Beach, Missouri. |
