Here's the window .. It has six rectangular panes separated by mullions. I designed the pattern to work with the mullions.
Each piece of glass on the pattern has been numbered. Most pieces are labeled with codes to signify what type and color of glass will be cut with it. This design has background glass of medium amber Artique glass. The stems will be cut in dark brown cathedral. The mullions will be made from dark amber and light amber streaky glass. The flower shapes will be made from medium amber and white wispy glass. And each panel will be accented with red and amber waterglass, as well as green and amber mystic glass. All of the glass chosen has similar opacity and are in similar color families.
Since this project is divided into six smaller windows, I'm cutting out patterns and glass for one smaller window at a time. Below, I've cut the pattern pieces and organized them into individual junk mail envelopes. As I cut each piece of glass, I draw an "X" to the pattern to be sure that none are re-cut. I've placed the pattern pieces face-down because the front of the glass is slightly textured which may interfere with a good score line.
Below, I'm cutting the glass. I'm using an oil-filled pistol grip cutter at a 90 degree angle to the glass. Applying even pressure, I press it against the edge of the ruler to get a straight line. (I would be pressing down on the ruler with my other hand which is holding the camera for this photo). Then I tap on the score line repeatedly with the brass end of the cutter. In many cases, the tapping is enough to separate the glass. In other cases, I use a pair of "running pliers" to snap the line apart.
After the glass is cut in a straight line near the outer border of the group of pieces, more cutting is done to get the shape needed. "Grozier pliers" and "running pliers" are the two main tools for this task, after intial cuts are done with the pistol grip cutter.
I cut the majority of glass by hand. Since many of the cuts in this pattern are rather complex, though, I'm also using my Gryphon Omni II Wire Saw. Its a large, loud machine but it does a wonderful job with precise cuts. In operates with a steady stream of water which covers the blade and the glass. To prevent the markings from washing off, I cover them with a layer of lip balm. Works like a charm.
And here is the first of six segments with all of the glass cut and put in place. As I work, I'll be trimming the glass for a better fit .. Not too loose and not too snug.
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