Here's a "before" photo with the upper left panel removed. I posted it to show the size of the panel, which is about 6' tall and 10" wide.
The first step in any repair is to find matching glass. Fortunately, I was able to find the lightly textured amber from another stained glass artist whom I happened to meet with on the same day that my customer dropped off the panel.
The clear glass was another story. I went on a road trip to Maryland and brought back some of what I thought was a perfect match, but it was too shiny. I then ordered the same style of glass, but from a different manufacturer in Washington State. Voila! Perfect.
So once I knew I had the correct glass, I went in, one piece at a time, and cracked out all the glass from the first affected piece as shown below. Needle nose pliers and safety glasses are essential at this stage.
Here I've traced the glass ..
And I scored it with this pistol-grip glass cutter. Here I'm using the metal end of the cutter to tap along the score line to make it crack. You may notice that it didn't exactly crack on a straight line like I wanted it to. That's typical for glass! Fortunately, the crack is outside the line, so I simply separated the piece and used another tool, groziers, to snap off the glass exactly at the traced line.
Next, the edges of the glass get run through a wet grinder. This is done to protect the fingers (I'm wearing "rubber fingers" here) and to allow the copper foil to adhere properly
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!