Wednesday, July 20, 2011

Octagonal window half soldered

More progress.  The front of the octagonal window has been tack soldered, meaning that the copper foil on the front side was brushed with liquid flux and soldered lightly at the joints, for stability.  Then the jig was released and the paper pattern was carefully slid out from underneath.  Here it is. (Click to enlarge any photo).
As you can see, the blue glass looks different on the homasote board than it did on the white paper pattern.  It will look different again when its freed from the table and in the light .. a lovely bright shade of medium blue. 

Once the window was freed from the jig and the pattern, I soldered the entire front side.  I use 60/40 solder (actually 63/37 representing 63% tin and 37% lead).  Its dangerous.  To protect my lungs, I use a Sperian P100 Respirator for Lead Removal as found in Home Depot for $12.98.  Its like having your own personal humidifier, something you get used to, and very effective.
Liquid flux is very caustic so I am always careful not to bring food into my work area, and I wash my hands immediately after use.

This window is approximately 28" across, and with all the glass and the solder, it will be a weighty piece.  Its a good design, balanced and well structured, but I wanted to provide an even longer life for this larger window.  I added lengths of Braided Wire Invisible Reinforcement between the glass pieces at several random places.  At $2.75 for 10', its also a worthwhile purchase.  Find it here.
See the silver braid between the copper-foiled piece of glass.  It becomes invisible when the solder is melted into that space.

Next, my husband will custom cut the metal "channel" framing around the border which will add strength and stability.  Then I'll carefully turn the window over, solder the back, clean it and wax it.  Stay tuned .. Construction to resume on Monday.  (We're off on a camping trip).

Boehm Stained Glass Studio website and FaceBook site.


  1. It is coming out great. Good idea to add the braided wire.

  2. Hi, I always read your blog and amazed by your passion in glass blogging and etching. Thanks.

  3. Thank you so much for your comments .. I enjoy every step of the stained glass process and am happy to share my work. If you're on FaceBook, you can follow my work there as well ..