Thursday, January 12, 2017

Glue Chip Glass panel Repair

This small panel was made by my customer about 25 years ago.  It was her first piece which I thought was very impressive!  She learned to work with bevels and cut curved and straight lines, and also framed the piece.  Since she no longer has her tools, she asked me to repair it for her.  Here's how I went about it ..

Here is the panel, showing cracks in the two pieces on the right side. The glass is called Glue Chip and is very popular.  It's also known as Jack Frost glass and is commonly used with bevels

Close up.  Notice how thin the chain is.  This was the reason for the damage.  The chain is too thin for the piece, and it eventually gave way.

Here I'm "scoring" one of the cracked pieces by cross-hatching it with a glass cutter as shown.

Now I'm using the metal back of the glass cutter to smash through the glass and remove all of it.

I've removed the old glass and the solder and foil that was around it.  Now I'm using a piece of Manila folder to trace the inner outline.  This will be used for the pattern.

The pattern is a perfect fit.

 I've traced the pattern onto a new piece of glass and I've scored a straight line.  Here I'm tapping on the glass to "loosen" it so that it will split.

The glass has been cut in more detail by hand, using the glass cutter.  Then I ground the edges using the electric grinder.  Here I'm applying pressure-sensitive 7/32" silver back copper foil to the edges.  I'm using silver back because the solder will remain silver.  Since the glass is clear, the inside of the foil will be visible.  By matching the interior color of the foil to the color of the solder (black or silver), it becomes essentially invisible.  

Now the new piece is in place.  I've shored it up underneath with a few squares of cardboard.  Its important that the new piece of glass be soldered in on the same plane as the rest of the piece.

The first piece is repaired and soldered in place.  Now I'm scoring the second cracked piece, to prepare for its removal.  Then I'll repeat the same process.

And here it is, fully repaired.  I removed the thin chain and suggested a heavier chain to prevent breakage in the future.

Here's another view which shows the nice textures of the glass.  Thank you Jane, for entrusting me with your first stained glass project.
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Wednesday, January 4, 2017

Frank Lloyd Wright Style Lamp Repair

This beautiful lamp may look familiar.  I repaired it once before, in late August of 2013 when it accidentally fell.  It took another tumble recently and its owner called me back again.  I was pleased to be able to again restore it as new.  To see the first time it was repaired, click here.  Otherwise, here's the process for the second time around ..

This time, the lamp took a far worse hit and sustained much more damaged.  Three sides sustained several cracks each.  Here's one side ..

And a view from the top.

And another view showing a smashed corner.

I decided to start on the corner, since this is an anchor point and would strengthen the lamp right away.  I've already made a template of the space and I've traced three new corner pieces.

Now I'm grinding the edges of one of the pieces.

Here's a spot where I'll be adding a new corner.  I've cleaned off the old solder and foil.  I've added new foil to the border.

Here is one of the three corners, in place and ready for application of liquid flux, followed by soldering.

Moving along to the side, I've made a paper pattern for this cracked piece.

Here's a view of the new corner piece in place surrounded by cracked pieces.

Another view, this time showing the replacement of one of the thin bottom pieces on the left side. The right side is ready for replacement.

Another view of glass that is ready for soldering with many remaining cracked ones.

Now this side is repaired and is awaiting the application of black patina, followed by a thorough cleaning, and application of stained glass finishing compound.

Another side, fully repaired.

Now all the repairs have been completed and the lamp has been thoroughly cleaned of all the liquid flux. Now I'm applying black patina to all of the silver soldered areas.  It instantly turns the solder black.  It is also thoroughly cleaned off, then allowed to dry.  The final step is the application, drying and buffing of the stained glass finishing compound.

And here's the lamp, fully repaired ..

Another side, good as new again ..

View from above.

View from above, on the light box, showing all the beautiful colors.
Thank you again, Ralph, for bringing your beautiful lamp back to me and letting me know its in in good hands!  I appreciated that.  May you enjoy it for years to come, with no more mishaps.  
For more information on my other projects, please click here to visit my website.

If you're on FaceBook, please click here to "like" my BoehmStained Glass Studio page to keep up with all the latest projects.  Thank you!

Thursday, December 29, 2016

Octagonal Stained Glass Sunrise Sunset Window

My customer, in Queens NY, commissioned me to create a window which is to be the focal point of his newly renovated kitchen.  At his request, I prepared several geometric as well as sunrise/sunset designs.  Here's the winner ..




My husband Eric began the process by traveling to Queens to make a paper template of the window.  Octagons can be tricky.  Sometimes the sides are unequal.  He made the template to be sure of an exact fit. 
Here I'm using the template to define the borders for the pattern pieces.  On the bottom layer are Manila folders, taped together.  Above that are sheets of carbon paper.  And on the upper layers, my computer pattern and the template.  

After I've defined the borders of the octagon, I'm now tracing the numbers and colors onto the pattern.

As each color pattern is cut out, I organize them in marked, recycled envelopes.  I'm using double bladed stained glass pattern shears which cut a thin channel of paper between each piece.  This bit of room is essential for the copper foil which will be applied later.

Using the template that my husband Eric made of the window, I'm tracing the border onto the computer-generated pattern.  This will ensure that the borders will be correctly sized.

I decided to start with the red glass.  I generally cut all of one color at a time. Here I'm tracing the pattern pieces with a silver Sharpie pen.

I cut each piece of glass with an oil-filled pistol grip glass cutter shown here.  I "score" the lines by pressing down firmly on the glass at a 90 degree angle.  Once the glass is scored, I tap all along it using the metal end of the cutter.  This is one way to "loosen" the glass to get it to split properly.


Another way I cut glass is with a wet ring saw, shown here.  It gives precise cuts every time.  I use lip balm over the markings to prevent them from washing away as the saw is running.


Another tool used to split the glass is "running pliers" shown here.  I place them at the end of a "score" and the glass will break cleanly.


As each piece of glass is cut, I bring it to the electric grinder.  Its important that the edges of each piece of glass be ground.  It makes them safe to handle, and it improves the adhesion of the copper foil which will follow.


As I grind and then clean each piece of glass, I place them on the pattern as shown.

This tool is called "groziers" and its used for nipping off thin sections of glass

Another example of "groziers" nipping off a piece of glass.

All glass is cut.


Adding braided reinforcement wire to several places between the glass, to strengthen the piece.

Applying copper foil to the borders of each piece of glass.

Using a "fid" to burnish the foil.

At this point, the center pieces of the panel have been "tack soldered" so that I can slide it onto the template.

The glass is all on the template now.  I'm marking glass to be trimmed around the edges.


The glass has been trimmed to fit the template.  Now I'm using a Dremel tool to sign/etch my name and date into the glass.

All the glass is cut, foiled and soldered on the front.  It's now ready for the zinc channel frame.



Finished!   Eric custom-cut a metal frame from zinc channel, which I soldered it to the border.  The window has been cleaned and waxed.  It will look different under different lighting conditions.  Here it is outdoors with the sun behind it, and also with a white board.



Here it is with a white board behind it.



Here's Eric doing a night-time installation in the new kitchen, about two weeks ago.

Here's a night-time view from outside the window.  I love how the sun pops!

And here is a photo taken by my customer the next day, in full sun.  Thank you for the photo, Manuel, and for the pleasure of meeting you!  May you enjoy your renovated kitchen and your beautiful window for many years to come! 
HAPPY NEW YEAR to you, and all of my Boehm Stained Glass Studio followers and customers!
For more information on my other projects, please click here to visit my website.

If you're on FaceBook, please click here to "like" my BoehmStained Glass Studio page to keep up with all the latest projects.  Thank you!