Friday, November 14, 2014

Small 6-Panel Stained Glass Lamp Repair

This lovely little lamp is special to my customer because it belonged to her Mom.  One of her cats accidentally knocked it over and broke the only one of the 6 panels which had the artist's signature and floral artwork.  Here's how I went about making the repair.  (Click on any photo to enlarge).

Here's the lovely little lamp.  The damage is evident in this photo.


Seen from inside, with the artist's signature.  I offered to save all the pieces of glass since the lamp is very sentimental.

The first step is to remove all the glass in the broken panel.  Here I'm pulling it out with needle-nose pliers.

Its also necessary to clean up the borders of the space.  Here I'm using my soldering iron to melt off the old copper foil and solder.

Now the borders are clean and ready for copper foiling.

Below, I'm using part of a Manila folder to create a pattern for the replacement glass.

Its a perfect fit.

Tracing the pattern onto the glass with a Sharpie pen.

Using a flat ruler to press against, I'm scoring the glass using an oil-filled pistol grip cutter.  (If I weren't holding the camera, I'd be pressing on that ruler with my left hand).

When the replacement glass is cut, I run the edges along the bit of the electric grinder.  This makes the glass safe to handle and allows the copper foil to adhere properly.

Here I'm applying 7/32" wide self-adhesive copper foil to the edges of the glass.

Next, I'm applying the same width copper foil to the edges of the open space.  Then I'm pressing the foil onto the glass using a "fid" or stiff plastic wand.

Now the replacement glass has been soldered in place.

Then I apply two strips of the copper foil to the outside of the seam in order to match the rest of the lamp.

Before doing any soldering, I apply liquid flux with a metal brush, as shown below.

View of the copper foiled seams.

Now the strips have been fluxed and soldered.  I'm applying Novacan Black Patina to the seams using a metal brush.  This chemical instantly turns the soldered copper foil from silver to black.  After each step in this process, I'm spraying the area with Kwik-Clean Flux and Solder Cleaner and wiping it off with a towel.

And here is the repaired lamp.  Thank you Lyn for entrusting me with this sentimental gem.  May it shine on for years to come, in memory of your Mom.
Please visit my website to see my custom windows and repairs (click here).  And if you are on FaceBook, become a fan and I'll keep you up to date on all my stained glass projects.  Call me any time at 201-600-1616 or email with your questions. Thanks!

Wednesday, November 5, 2014

Stained Glass Kitchen Cabinet Panel made into a Window Hanging

Inserting stained glass panels into kitchen cabinet doors is a popular way to decorate and personalize a kitchen.  Stained glass pieces, properly cared for, last dozens of years.  In many cases, the kitchen needs renovation before the stained glass does.  This blog entry shows the process of re-purposing a pair of Iris-themed kitchen cabinet panels.

Here are the pair of Iris panels as they came to me.  I added a Post-It note to the top to indicate the front of each panel, at my customer's preference, since either side would look good.

 Her request was to simply add hanging hooks so that her mother could put them in the windows of her new apartment.  However, this panel was not reinforced with a metal frame. Without the reinforcement, the hooks would have eventually caused the panels to crack.  Below, see that I've added a thin zinc "channel" frame to the sides and bottom of the panel.  Holding the metal framing in place is a "jig" or "fence" which is pressed against the frame and held in place with push pins.


Notice below that I've soldered the existing solder lines directly to the metal reinforcing frame.  I've also soldered the mitered corners at the bottom of the panel.  

In order for the existing lead lines to accept new solder, its necessary to burnish off the patina using a thin gauge steel wool as shown below.

Now the frame is in place and I've soldered a small metal ring to the back of the panel as shown.  The ring is a "jump ring" which has been tinned.  This means I coated it with liquid flux and brushed on a thin coating of solder.  I also added a small amount of solder to the frame at the spot where I wanted to attach the ring.  Holding the ring in place with needle-nosed pliers, I applied the soldering iron to the ring which caused the solder on both the ring and the frame to melt.  Then the hook becomes strongly bonded to the frame.  It will now support the weight of the panel.

Another view of the soldered-on "jump ring".  The metal is wet because I had just applied black patina to it.

Here is a view of the finished panel.  Its actually sideways in the holders that my husband Eric made for me to display my work for photos.
 Here is another view, showing the ring on the top side.  The ring on the opposite side is not visible.  This is a wonderful way to re-purpose kitchen cabinet stained glass panels.  To see more examples of kitchen cabinet panels, please click here.  This project will be listed first, followed by several others.  When you get to the bottom of the page, click on "Older Links" to see more.  Thanks!

Please visit my website to see my custom windows and repairs (click here).  And if you are on FaceBook, become a fan and I'll keep you up to date on all my stained glass projects.  Call me any time at 201-600-1616 or email with your questions. Thanks!

Thursday, October 30, 2014

Leaded Stained Glass Custom Sailboat Window Collaboration

This project has been in the works for about 10 months.  I'm pleased to report that it was installed two weeks ago.  We had repaired a large Shamrock-themed stained glass window for a customer back in May of 2012.  See that project here. She was so impressed with our work, that she called me back at the end of last year and asked me to work with her to create a custom stained glass Christmas gift for her husband.  The subject was to be his beautiful racing sailboat. I realized that my studio would not be able to handle it due to the size .. 67" wide by 34" high.

Here at Boehm Stained Glass Studio, we always do what's best for our customers.  Since I knew this project was too large for us, I brought in a trusted colleague, an artist who works mainly with "leaded glass" as opposed to "copper foiled" or "Tiffany style" stained glass, which is my area of expertise.

"Leaded glass" can be found in older homes and is characterized by thick lead lines which are soldered only at the intersections.  It is the preferred technique to use for large pieces and for windows which are exposed to the weather.  My technique, "copper foiled" or "Tiffany style", is well suited to indoor residential windows of approximately 30" or less on all sides.  Both use similar clear or colored glass, but the techniques, expertise, and tools required differ greatly.

My role in this venture was to design the window and to coordinate the installation.  My collaborating artist did the entire fabrication at her studio.  It took several months between the initial design concept and the fabrication and installation, because we were waiting for renovation of the home to be completed.

Below is our working photo of my customer's 46' sailboat called "Testing Life".  It is a 1996 Tartan 4600 docked in South Jersey.  My Dad owned a 32' Albin Sport Fisher, so I'm very familiar with the boating lifestyle.  Even though our boat was a cabin cruiser, I had an immediate affinity for the family's love of boating. Our boat was the centerpiece of our Summers, as is theirs. Here are photos of the boat and the process to create a tribute to it in stained glass:  (Click on any photo to enlarge).

Below is the pentagon shaped window where the stained glass sailboat is to be installed.  Notice the peaceful view of the lagoon.

Here is the sailboat.  The family of five with their two dogs were on board.

Below is my design which includes each family member.  My customer and I had a few discussions specifying her wishes for the finished window.  The design below incorporated her vision of what the window would be.

This past August, my husband Eric and I came down the shore to visit our customers at their new home, take photos, and prepare the paper template, below.  Eric routinely prepares a paper template for any unusually-shaped window, to be sure of a perfect fit at installation time.  We then prepared three full-size copies of the pattern, the original template, all the measurements, other photos of the room, and a full-color rendition of the pattern above, to my collaborating artist.

Below, a photo of the window still on the work table.  Her studio did a beautiful job, using flashed glass to etch in the name of the boat and the numbers on the sails.  

In this closer-up view, (click to enlarge) the family members and their two dogs can be seen.  Colors for the dogs, hair color and baseball cap, was specially chosen to represent each member of the family.  The white deck and windows were painted on.  Some smaller areas were rendered in copper foil. The studio did a fantastic job of interpreting my design.


About two weeks ago, her crew headed down the shore and installed the window.  Here it is!  

Another view of the completed, installed window.  As a first-time collaboration, I'm very pleased with the results.  It was a joy to have my design interpreted so beautifully by a fellow artist.  My customers are equally pleased.  We hope they enjoy this tribute to their sailboat for many years to come!

To see more of my stained glass work, please visit my website (click here). And if you are on FaceBook, become a fan and I'll keep you up to date on all my stained glass projects.  Thanks!

Tuesday, October 7, 2014

Boehm Stained Glass Studio Tour

My current project is a collaboration with a fellow stained glass artist.  For several months, we've been working with my customer down the shore to design and build an approximately 6' x 3' window which depicts her husband's beautiful racing sailboat.

So while things are are relatively quiet here, I thought it might be interesting to give a tour of Boehm Stained Glass Studio, where I create custom residential stained glass windows and do repairs of windows and lamps. Here's a behind-the-scenes look at where the magic happens!  Captions are below each photo. (Click any photo to enlarge).

My husband Eric has a similar sign on his workshop door.  We spend hours down here working together.  He makes scratch-built balsa wood airplanes!  We have a habit of knocking on each other's door, to ask permission to enter.  (We look around for a moment, and then say "yes").

(Above) I keep small items on the wall in front of my glass cutting table. On the left is a re-purposed metal CD holder mounted sideways.  It holds film canisters with small bits of solder for tinning, a small container with Q-Tips for cleaning the corners of glass pieces after waxing, a small bin with scissors and pens, a large supply of various sizes of copper foil, lots of acid brushes, black and silver Sharpies, and many hooks to solder onto the backs of frames.
On the right side I keep supplies of tape, stained glass paint, Staples rubber fingers in various sizes, plastic tubing for my electric glass cutter (photo to follow), and various liquids and chemicals including cutter oil, Clarity Stained Glass Compound, copper and black Novacan patina, liquid flux, grinder water conditioner, and Goo-Gone.

(Above) This is where I generally do all the glass cutting.  On the left are gardening gloves which I use for handling sheets of glass.  In the left corner I've got my groziers, running pliers, needle-nose pliers, pattern cutters, pistol grip glass cutters, and scissors.  In the center are packages of Strongline reinforcement, braided reinforcement, 60/40 solder, a container for the Staples rubber finger protectors, and a small brush and pan to keep my work surfaces clear of glass fragments and beads of solder.  And on the right, of course, is my trusty glass grinder.  My husband installed an outlet specifically for it which turns on and off with the light switch. Also of note is my work surface which is Homasote, a sound-proofing board which is available at any Loew's or Home Depot.  It takes push pins well, is somewhat fire resistant, and has a soft, spongy surface which is ideal for cutting glass.

(Above) Here's another view of the left side of my cutting table.  It shows a plastic shoe box filled with junk mail envelopes where I store pattern pieces after projects are completed. Also visible is a breathing mask I use when I solder, and two navy blue aprons, one of which I wear whenever I'm working.  Stacked in the corner are large plastic pretzel jars which are perfect for storing solder, glass rondelles and colored pencils.  On the walls are hand-written thank you notes, notes of encouragement from my hubby, stickers removed from purchased glass, and a few old patterns for inspiration.

(Abocve) This wooden file cabinet holds a stack of clean old dish towels on top, which I use for drying and also applying finishing compound.  The towels are resting atop an informal collection of books full of supplies to purchase and patterns for inspiration.  I keep all the pattern pieces from every project, identified and in order, in Pendaflex folders.  The top drawer holds a supply of old manila folders for patterns, a package of carbon paper, and a supply of cardboard in various thicknesses.

(Above) In the mid-eighties, I was a rubberstamp artist.  For over 3 years, I wrote bi-monthly articles and had work published frequently in Rubberstampmadness Magazine under my "nom de stamp", "Miss Rubbaloid".  These custom made cabinets held my collection of nearly 5,000 rubberstamps, most of which I still have.  Now they work perfectly for glass.  Each drawer is labeled with the color of the glass for easy retrieval.

(Above) Another view of my glass storage cabinets. I keep a supply of cardboard packing material and more glass underneath the cutting table. I found the tractor chair in Target about 2 years ago.  It rolls around easily on the tile floor which I sweep frequently.


(Above and Below).  Here are two more storage areas for my glass, arranged by color.  These were home-made units which I purchased from a stained glass store which was going out of business.   They are attached back to back, with wheels on the bottom for moving when necessary.

(Above) Here's my secondary work surface where I generally build stained glass windows and repair lamps.  On the right corner is a box of jewelry findings and beads.  (I sometimes make jewelry as well, but just for myself).  Both soldering irons can be seen resting on a small brick, as well as a small flower pot which I stuff with wet paper towels to clean the tip of the soldering iron, and yet another breathing mask.  

This may just look like a stack of funky old Parisian shoe boxes .. and it is .. but the boxes contain pieces of 45-year old glass gifted to me a few months ago by a kindly older gent who was giving up his hobby.  This is the first place I check when an older lamp or window comes in for repair. The glass he's given me has been a perfect match for repairing several older pieces. 

(Above) Here's another work surface.  I use this for building windows, doing repairs, or glass cutting.  I just move my tools from place to place.  We bought this table from the inventory sale at a local Borders bookstore! My Dremel tool is here, which I use to sign my name and date to custom windows.  Also on the table are my part-time photography assistants, Phil and Philomena Foamhead .. I sometimes employ them for lighting experiments when I'm preparing for a shoot.  (Click here to see my event photography website).
On the left is a rolling colored-bin glass holder, purchased recently at Michael's.  I keep smaller pieces of antique glass here.  On top of it is a white plastic bin which holds all the hardware when we do a window installation.  The pink carpenter's bag on top was a gift from Eric, but he's the only one who uses it.  It holds everything he needs to do the installations .. Caulking gun, caulk, hammer, brush and pan, tape, cardboard, the works.
On the floor is a holder which Eric made with vertical plate holders found in the Container Store.  He nailed them to a piece of plywood, then added wheels.  Here I store larger sheets of glass that won't fit in my custom cabinet drawers.  Some antique glass is here as well.
In the laundry room is the good old utility sink where I rinse off all glass after its been grinded, and where I sometimes clean off finished windows and lamps.  I sometimes use the kitchen sink upstairs.  It depends on the size of the finished piece.

This is my electric Gryphon Omni Wire Saw Glass Cutter, used only when I have cuts that are too intricate to be done by hand.  Its very loud (I have to use earplugs) and its intimidating for that reason, but it does a great job.  99% of my work is hand-cut, though.

I always keep a good supply of 6' lengths of wood for framing, as well as zinc and brass channel.     

And that concludes our tour!  Hope you enjoyed it!  Give me a call if you have an idea for a custom residential stained glass window .. or if you have a lamp or a window that you no longer display because its cracked.  Let me fix it for you and give a new life!  Call 201-600-1616 or email me at Kathy.Boehm@Verizon.net and we'll get started right away.

To see more of my stained glass work, please visit my website (click here). And if you are on FaceBook, become a fan and I'll keep you up to date on all my stained glass projects.  Thanks!