Thursday, September 21, 2017

Repairs to Stained Glass Wedding Hearts Panel

This unique panel was made by my customer as a wedding gift for his bride twenty years ago.  He used to do stained glass, and this is evidence of his expertise and creativity.  After he designed and created the panel, he asked each wedding guest to etch their name into the hearts.  The panel was damaged and so he came to me to repair it.

Here's how it came to me with both corners snapped off and with several cracked pieces in the bottom row.

I began by removing old copper foil and solder from the upper corner.  Laying nearby is the replacement piece of green, to which I've already applied new copper foil.

In preparation for the attachment, I'm using a hand file to roughen up the edges of the glass.  This helps the copper foil to adhere better. The signatures can readily be seen in this photo.  Its irreplaceable.

With the new corner piece in place, I'm applying liquid flux to the foil.  This helps the solder to flow evenly.

Now the new piece is in place.  Notice that I replicated the decorative solder as well.  A nice touch.

 Here I'm using steel wool to remove old patina so that I can solder the adjacent piece of glass.

Making a pattern for the replacement pieces in the other corner.

Tracing the pattern onto the glass.

This beautiful panel was created using opalescent glass, which tends to be more difficult to cut than cathedral, or transparent, glass.  Therefore I used my wet saw to do the job.

Using the glass grinder to smooth the edges of a replacement piece.

Now the corner has been repaired.

Moving onto the bottom, there are a few pieces where cracks can clearly be seen.

I've scored one of the cracked pieces by cross-hatching the surface with the glass cutter.  Here I'm carefully banging out the piece with the metal end of the cutter.

Now the piece has been removed and I've prepared and traced the new replacement glass.

With that piece in place, I moved on to the adjacent one.

Now that one is repaired.

Another view of another pattern in place, awaiting replacement.

After all of the cracked pieces have been replaced, I'm spraying the surface with a cleaner which neutralizes the flux.

Here my husband Eric is fitting a custom frame onto the piece.  Not pictured is the end process whereby I solder the lead lines to the frame in several places on the front and back.  

And here is the finished repair, minus the zinc frame.  (A first for me, I didn't take an "after" photo). Many thanks to Rich for entrusting this special piece to me.  May you and your wife enjoy it for the next twenty years!

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!



Friday, September 15, 2017

Dutch Stained Glass Suncatcher Repairs

This lovely trio of sun catchers was owned by my customer's late mother.  She is from our town, Midland Park, NJ which was settled by the Dutch in 1894.  Around town there are several windmills surrounded by tulips on front lawns. These were very meaningful to her and I was happy to repair them for her.  Only two of the three needed repairs.

Here is the windmill which sustained several cracks in the lower corner.  Note that these windmills are constructed using lead came, not copper foil.  I don't usually work with lead came but since the repairs were basic, I took them in.

 Using the glass cutter to score the glass to prepare it for removal.

Now all of the cracked glass has been removed.  I used the inner border to draw directly on the replacement glass for a good fit.

Scoring the border of the replacement piece.

Grinding the edges of the glass.

And here is the completed repair.  I worked the glass inside the borders of the existing came.  Since it is a soft media, the glass was a good fit.

The little Dutch girl has a crack in her bosom and there's a piece cracked out of her skirt.

Here I've scored the yellow area and I'm using the metal end of the cutter to crack out the glass.

Now I've traced a new piece of glass for the replacement.

Using running pliers to snap the glass. I went back with the glass cutter to score and remove the glass around the outline.

After the glass is properly cut and ground, I'm now inserting it into the boundaries of the lead came.

Now both suncatchers are repaired.  Notice that I replaced the original old hanging hooks with new ones.

And here's the trio, including the Dutch boy which did not need repairs.
Thanks for bringing these to me, Cindy!  I'm happy to know that they are back up in a window here in town.

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!


Monday, August 28, 2017

Hundred Year Old Stained Glass Lamp Repair

My customer told me this lamp belonged to her grandmother and that it is 100 years old.  Fortunately, none of the glass was broken, or it would have been difficult, if not impossible, to replace.

Here's how it came to me, with the glass panel out, and the surrounding areas compromised.

As with most older lamps, the edges of the glass were not ground before foiling.  I'm doing that here.  It improves the adhesiveness of the foil.

Here's another look at the damaged side.

Safety is important when working with stained glass.  Here there's visible white smoke rising up from where I'm melting off old solder and foil.  I'm wearing a protective breathing mask and I have a filtered fan on as I work.

Now I've lined the borders of the area with new copper foil.

I decided to remove an adjacent piece was was loose, and was letting light in.  It's also been copper foiled.

 Here I'm applying liquid flux to the copper foil.  This acts as a catalyst to help the solder flow freely.

After those two pieces are soldered in place, I began work on the border.  Here I've push-pinned the border foil in place. I added new foil to the outer edge and soldered it to the new lead lines at the top of the replaced pieces.

After cleaning off the area, I'm now applying black patina to the newly soldered areas.  It instantly turns the patina black.

And now its repaired!  This is the view from inside the shade.

And a final view from outside.  Thanks to Loretta for entrusting me with your precious heirloom.  Now you can enjoy it for many years to come!
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!

Tuesday, August 8, 2017

Stay tuned .. Vacation time!

We'll be back after our vacation to the Pacific Northwest which will include witnessing the total eclipse!  I've got a few projects yet to post, with more on the way.  I've also upgraded my computer.  Along with that came new photo software which I have yet to learn.  But I think it'll be worth the wait!  Stay tuned.
Thanks!

Monday, July 31, 2017

Green Floral Stained Glass Lamp Repair

Yet another gorgeous lamp to repair!  (I've done over 100 so far).  This one is mostly green with some orange flowers around the sides.  The glass colors are spectacular. Here's the process to bring it back to new again.

Here's a view of the lamp with the cracked pieces marked with blue tape.


Another view of the damages which extend over half of the border.

After assessing the damage, I'm beginning to remove the worst-cracked pieces with needle nose pliers.

I've removed every other cracked piece and will repair them in that order.  I do this so as not to weaken the structure.  I'm using a hot soldering iron to melt off the old copper foil and solder.

Manila folders make great templates.  Here I'm tracing openings to prepare new glass patterns.

Tracing new pattern pieces onto the glass with a Sharpie.  Each piece gets a number.

These blue running pliers snap the glass after I score it with a glass cutter (the purple tool on the work surface).

Each new piece of glass gets its edges ground.

After the piece is cut, ground and fitted, I apply adhesive copper foil to the edges.  I also apply copper foil to the borders where the glass will be inserted.  Here I'm applying liquid flux to the foil.  This is a catalyst which enables the solder to flow freely.

Now this section of the border has been repaired.

Not all of the pieces had to be replaced.  Some of them were just loose.  Here I'm using a razor knife to scrape off old adhesive.  This piece will be re-inserted into the lamp.
 Here's the process of burnishing the foil onto the glass using a fid, or flat plastic wand.

Now I'm building the border back up again, piece by piece.

Cutting another piece of glass.  Matching the glass is very important to me. Since green is such a popular color in lamps, I have a large inventory of different textures and colors in inventory.

 Now all the cracked pieces have been replaced.  I'm applying black patina to the solder.  It turns the solder black instantly.  After it sets for a while, I wash it off with a spray cleaner called Kwik-Clean.  After it dries, I cover the inside and outside of the lamp with stained glass finishing compound.  This is a light wax which protects the patina and shines the glass.

And here is this beautiful lamp, repaired and ready to be enjoyed again.

Another view.  Thank you Rosemary, for the pleasure of meeting you and for allowing me to repair this beauty!
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!