I started this in the last post Create a stained glass project by drawing an image and then resizing it to the correct size for the window. I made a frame out of 1 x 1/2 wood strips screwed to plywood and added that Zinc frame on the edges. The image has been resized Glass panels I purchased for this project. Next the image was transferred Sample paper with Carbon paper for transferring. The pattern is cut out using Pattern scissors that offer enough space for the Copper foil around the edges of the cut glass. Below you can see the blue and brown copper foiled mountains, as well as the sun and sky, which have been cut and then sanded to match as closely as possible. The image was placed as a guide for the glass pieces when cutting and fitting them into the frame.
This is the first rough cut of a bird to which the pattern has been glued using the glue stick shown.
A closer image of the bird with pattern glued to the glass before cutting. The glass cutter I used is pictured next to the glue stick. The glass panels you can purchase are 12″12″, 16″X16″ or larger if you order them in bulk.
The bird and sky have been cut, fitted and copper foiled as the progress is made from the bottom to the top of the window, the glass pieces becoming slightly larger or smaller as needed to fit the frame size. The pattern is uncut at the top of the window and I make adjustments to it over time.
A A diamond band saw is used for more difficult cuts. I try to keep the pattern as dry as possible to prevent it from coming off the glass as it still needs to be sanded to fit the pattern.
This is what it looks like after it has been cut and sanded with the band saw Diamond cutter.
The second bird with the individual fathers lies on the glass ready to be cut. When laying out, pay attention to the grain of the glass.
The top half of the window is installed with the bird being the last.
In order for all the parts to fit, a lot of grinding and assembly work is required. When cutting open the bird’s body I had a bad break as the tail broke and I didn’t have enough of the glass to make a new one so a joint had to be used.
All parts are assembled and ready for the copper foil.
The next step is to solder all the copper foil connections and the zinc frame connections using a good solder adjustable heat soldering iron and 60/40 lot and liquid flux.
After the soldering is completed on both sides of the window, I use flux cleaner to wash the glass, then I use it black patina for coloring the solder joints.
To frame the window I used Oak frame available from your glass supplier. It has been cut to size and then stained in the color of your choice, mine is light oak which shows the grain of the wood.
Below you can see the finished window as the sun shines from outside.
I haven’t started another project right now, but as always one pops up, so until the next post I wish you a Merry Christmas and a Happy New Year.
