History & How to Make Stained Glass
- 1). Place one copy of the pattern on the work surface and secure it in place. Cut another pattern into pieces with the scissors or stained glass pattern shears and use the last as a reference for color and piece placement. The stained glass pattern shears are special scissors with three blades that cut the lines out to compensate for the space between the glass pieces that will be taken up by the copper foil.
- 2). Fasten the straight-edged wood or metal strips to form a right angle along the bottom left or right-hand side of the pattern. This can be useful even if the pattern does not have straight sides.
- 3). Trace each piece on the appropriate glass sheet. Cut the glass by scoring along one of the pattern lines with the glass cutter; start the score at one edge of the glass and score all the way to the other edge so the piece can be broken off. Use the glass pliers to break the pieces apart unless they are big enough to break apart comfortably by hand. Repeat this process for each line of the pattern piece. Placement of the pattern piece to reduce glass waste is an important consideration.
- 4). Use nails as needed to help hold pieces in place.
- 5). Grind the sides of each piece of glass as required to smooth the edges and shape the piece further if needed.
- 6). Wrap each piece of glass with copper foil, centering it carefully along the edge so that it folds over evenly on each side.
- 7). Burnish the edges with the burnishing tool, smoothing the foil down on the edge, then each side so that it sticks firmly to the glass.
- 8). Fit the pieces together on the pattern and brush flux on the copper foil seams. Brush as many seams as can be soldered in about one-half hour--this may vary depending on soldering experience.
- 9). Melt solder along the seams with the soldering iron. Melt a thin layer first to cover the copper foil with solder, then melt the final seam, which should be smooth and slightly rounded.
- 10
Clean the flux off, turn the piece over and flux and solder the other side. - 11
Clean the whole piece thoroughly and apply the patina if desired as per the manufacturer's instructions. Apply carnauba wax to help polish the glass and protect the lead from oxidation.
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