Tuesday, June 28, 2011

Octagonal window pattern

My newest project is the design and construction of a 29" interior octagonal window which will separate my customer's kitchen from her living room.
I presented several octagonal designs for her consideration ... Here is the winning choice.
My customer requested mostly clear glass with blue accents to match her kitchen.  Here is a software rendition of what the finished window will look like.  The blue glass will be rough rolled and the clears will be rough rolled, glue chip, hammered, and crystal ice, to provide an appealing combination of textures.
The challenge with this design is that the opening in the wall is not symmetrical.  The lengths of the sides vary from 11" up to 12-1/2".  This necessitated special care in measuring and construction.

To assure the best fit, we made an exact-size cardboard template of the opening.  I then prepared the pattern based on the template, allowing 1/2" all around for the sturdy metal channel framing which will reinforce the piece prior to installation.

The window itself will have internal reinforcement with the addition of invisible braided copper wire between many of the glass pieces. The window will be framed with painted, custom cut wood which will fill the opening.
Shown above are the three stages completed so far.  The bottom layer is the cardboard template, followed by the white paper pattern which was created primarily with software with some measurement adjustments, followed by the creation of the working pattern which was traced onto manila folder paper using carbon paper.

The manila paper pattern will be cut apart with pattern shears.  Then the pieces will be organized into envelopes by color and type of glass, and used as templates to trace and cut the glass.
The glass has been ordered and is due to arrive later this week.  With vacation coming up next week, work will resume upon our return.  This is sure to become another beautiful custom creation .. Stay tuned for updates!

Thursday, June 23, 2011

Blue Jay and Nuthatch stained glass panels installed

I prepared these 6" x 11" bird panels for installation the same way as the Cardinal completed last week. I soldered on 4 small brass clips, 2 on each side of each panel, as shown below.  These clips slid underneath the mullions on the back door.

Since this project was a "fill in" job started in April, the solder had oxidized a bit, so I needed to go over it with steel wool #0 in order to prep it for the black patina.  That done, I waxed and polished each panel.

Eric unscrewed the lower portions of the mullion and then we lifted it up and positioned the birds underneath, catching the brass clips as we went. They are securely locked in now.  To see the entire process which I repeated for each of the three birds, click here.  (Click on any photo to enlarge).
These birds add new life to the back door!  I'll be happy to make a custom door panel for you in any theme or color.  Call 201-600-1616.

Today I started the design process for a new commission, a 29" octagonal window.  Stay tuned ...

Click here for Boehm Stained Glass Studio website (and if you will, please "like" our new FaceBook page). Thanks!

Thursday, June 2, 2011

Stained glass cabinet panel completed

Another window completed!  This was a different challenge, to duplicate an existing window.  The one on the left is the original.  The one on the right is my copy, 1" wider.  (Click photo to enlarge).
 
A lovely note of thanks from my happy customer!

Dear Kath,
I was so so excited when I saw the finished product of my stained glass door insert! You did such an incredible job of matching the other panels -- now my kitchen matches again. I loved watching the progress of the workmanship on your blog. Please thank Eric for me for hanging everything back up. And thank you, Kath, for such beautiful craftsmanship... I am so pleased!

Kathi

Thank you Kathi!  It was a pleasure meeting you and restoring your kitchen panel. I hope you will enjoy it for many, many years to come!

Next project: An octagonal interior window.  The design process will be underway shortly.

Click here for Boehm Stained Glass Studio website.

Wednesday, June 1, 2011

Stained glass cabinet panel soldered

As of this morning, the panel has been tack soldered, the jig removed, and the pattern slid out.  The panel was then fully soldered front and back and strengthened with the addition of a thin metal "channel" frame around the perimeter. (Click to enlarge photo).
The original window which I duplicated did not have this frame but I made an allowance for it when I prepared the pattern because the frame gives the piece more strength and stability.  It is very thin, about the same width as a lead line, so it will be hidden under the cabinet mount.  With the added strength of this frame, it can be taken out of the cabinet and used elsewhere.

Tomorrow afternoon will be the "big reveal" .. A side-by-side photograph of the original window beside the duplicate.  See if you can tell the difference.  Stay tuned.

Click here for Boehm Stained Glass Studio website.