Octagonal Stained Glass Sunrise Sunset Window

My customer, in Queens NY, commissioned me to create a window which is to be the focal point of his newly renovated kitchen.  At his request, I prepared several geometric as well as sunrise/sunset designs.  Here's the winner ..

My husband Eric began the process by traveling to Queens to make a paper template of the window.  Octagons can be tricky.  Sometimes the sides are unequal.  He made the template to be sure of an exact fit. 
Here I'm using the template to define the borders for the pattern pieces.  On the bottom layer are Manila folders, taped together.  Above that are sheets of carbon paper.  And on the upper layers, my computer pattern and the template.  

After I've defined the borders of the octagon, I'm now tracing the numbers and colors onto the pattern.

As each color pattern is cut out, I organize them in marked, recycled envelopes.  I'm using double bladed stained glass pattern shears which cut a thin channel of paper between each piece.  This bit of room is essential for the copper foil which will be applied later.

Using the template that my husband Eric made of the window, I'm tracing the border onto the computer-generated pattern.  This will ensure that the borders will be correctly sized.

I decided to start with the red glass.  I generally cut all of one color at a time. Here I'm tracing the pattern pieces with a silver Sharpie pen.

I cut each piece of glass with an oil-filled pistol grip glass cutter shown here.  I "score" the lines by pressing down firmly on the glass at a 90 degree angle.  Once the glass is scored, I tap all along it using the metal end of the cutter.  This is one way to "loosen" the glass to get it to split properly.

Another way I cut glass is with a wet ring saw, shown here.  It gives precise cuts every time.  I use lip balm over the markings to prevent them from washing away as the saw is running.

Another tool used to split the glass is "running pliers" shown here.  I place them at the end of a "score" and the glass will break cleanly.

As each piece of glass is cut, I bring it to the electric grinder.  Its important that the edges of each piece of glass be ground.  It makes them safe to handle, and it improves the adhesion of the copper foil which will follow.

As I grind and then clean each piece of glass, I place them on the pattern as shown.

This tool is called "groziers" and its used for nipping off thin sections of glass

Another example of "groziers" nipping off a piece of glass.

All glass is cut.

Adding braided reinforcement wire to several places between the glass, to strengthen the piece.

Applying copper foil to the borders of each piece of glass.

Using a "fid" to burnish the foil.

At this point, the center pieces of the panel have been "tack soldered" so that I can slide it onto the template.

The glass is all on the template now.  I'm marking glass to be trimmed around the edges.

The glass has been trimmed to fit the template.  Now I'm using a Dremel tool to sign/etch my name and date into the glass.

All the glass is cut, foiled and soldered on the front.  It's now ready for the zinc channel frame.

Finished!   Eric custom-cut a metal frame from zinc channel, which I soldered it to the border.  The window has been cleaned and waxed.  It will look different under different lighting conditions.  Here it is outdoors with the sun behind it, and also with a white board.

Here it is with a white board behind it.

Here's Eric doing a night-time installation in the new kitchen, about two weeks ago.

Here's a night-time view from outside the window.  I love how the sun pops!

And here is a photo taken by my customer the next day, in full sun.  Thank you for the photo, Manuel, and for the pleasure of meeting you!  May you enjoy your renovated kitchen and your beautiful window for many years to come! 
HAPPY NEW YEAR to you, and all of my Boehm Stained Glass Studio followers and customers!

For more information on my other projects, please click here to visit my website.

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Octagonal window installation

The best part of creating these windows is "big reveal".  Even though she had been following the building process on this blog, my customer was pleasantly surprised to finally see her window "in person".

This 27" octagon, as mentioned in earlier posts, was not a true octagon because each of its eight sides ranged from 11" to 12-1/2" in length.  Making a template for this space was essential.  Our efforts paid off.  It fits well.

My husband Eric brought along the compound radial arm saw.  He cut most of the wood on-site, to assure accuracy.  We used primed quarter-round molding which we painted a satin white in advance, to match my customer's existing moldings.

As each piece was cut, Eric brought it inside to nail after drilling pilot holes. He puttied the spaces between the wood and touched up with white paint for a flawless look.

Here is the finished window installed in a wall which separates my customer's living room from her kitchen. (Click to enlarge).

Below is the view showing how the blue in the window picks up all the blues in her kitchen.  From the living room side, the window accents the blue in her sofa and accessories.   

This is an elegant, simple and timeless design which, as I like to say, "adds character and color" to her home.  Call me .. I'd love to build one for you. 201-600-1616.

Next project:  A 17" x 35" window with almost 300 pieces of glass, and eight smaller windows above it.  Another stunner.  The glass has been ordered and the pattern making process is underway.  Check back soon to see the design and watch it being built, start to finish.

Boehm Stained Glass Studio website and FaceBook site.

Octagon window in the light

Here is the completed Octagon stained glass window, off my work bench and in the light.  (Click to enlarge any photo).

Here's a close-up showing the beautiful textures of the clear and blue glass. (Click to enlarge).

All that's left to do now is to wax it, sign it and install it.  I unobtrusively etch my name with the date (month and year) into each window. 

Stop back this weekend to see the installation process, and it see where it will "live" for the next maybe hundred years.  And stay tuned for my next project in the works .. Details on the way.

Boehm Stained Glass Studio website and FaceBook site.

Octagonal window completed

Just about four weeks after we started, the 27" wide octagonal stained glass window is completed.  After the most recent post, I soldered the back of the window.  Here it is, back in the jig, with the metal channel frame that my husband custom cut for each of the 8 sides, which are slightly different lengths. (Click to enlarge any photo).

After the channel framing was cut, I soldered each joint and linked it to the lead line, as shown below.

This adds a great deal more strength and stability to the window, which now weighs 7-3/4 lbs.  After soldering all the joints on one side, I carefully turned it over, soldered the back, and removed the jig.

Then, wearing rubber gloves, I scrubbed each side of the window, one section at a time, with powdered cleanser and an old dish brush.  This removed all the caustic flux, the soldering residue, and the markings used in construction. 

Here is the window just after being washed.  It is now being left overnight, laying flat on a towel, to dry completely before waxing. (Click to enlarge).

 

 Here's another view of the completed window.

Now you can see the different textures of the clear glass, and the brilliant blue waterglass which will complement the colors in my customer's kitchen.  (I'll post more photos of the completed window tomorrow).

Next, I'll paint the quarter-round wood molding that my husband will use to mount the window in the wall opening.  Check back to see the window in its new home. We'll be doing the installation this weekend.  

Boehm Stained Glass Studio website and FaceBook site.

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.

Octagonal window foiled

Moving along .. The approximately 27" wide octagonal window has now been foiled using 50' of 7/32" silver-backed adhesive copper foil.  After taking great care with the custom pattern and the cutting, each piece of glass fits nearly perfectly in place. To prevent the pieces from fitting too snugly and possibly cracking during soldering, I removed some of them and ground them down a bit.  (Click to enlarge photo).

Since this window is primarily clear, my customer and I decided to leave the lead lines the natural silver color of the solder.  Also because of the transparency of most of the glass, I used silver-backed foil as shown below.  (If you look "inside the glass", you'll see a thin band of silver).

The silver-backed foil will become practically invisible once the copper foil is coated with flux and soldered.  That's the next step .. stay tuned.

Boehm Stained Glass Studio website and FaceBook site.

Octagonal window glass cut

Back on track after a surgical procedure sidelined me for a couple of days this week.  Full steam ahead from here!  All of the glass is now cut for the octagonal window. (Click to enlarge photo).

Thanks to careful cutting, each piece of glass fits nicely after some minor trimming here and there.  Each piece has a tiny bit of "breathing space" in between, to allow for the copper foil which will follow.

Notice that the jig is still in its original position, to contain the glass until after it is tack soldered.  As is the case with all stained glass windows, the true beauty of the window can't be seen when its laying on the pattern.  The blue will be much more rich and transparent and the clears will glow as soon the window is lifted from the pattern and placed in the light.

The cuts on this design were mostly straight with a few soft curves, so I did all of the glass cutting by hand.

Tip:  Grinding glass requires that it be held firmly against the grinding wheel, which is wet by a damp sponge as it spins.  To protect your manicure, and to safeguard against glass cuts, always wear Staples Cosco Rubber Finger Pads.  At $2.29 for a dozen, you can't go wrong .. And they come in two different sizes.  Find them here.

The next step will be applying copper foil to the edges of each piece of glass.  I'll post an update as soon as that process is complete.

Boehm Stained Glass Studio website and FaceBook site.

Octagonal window pattern cut and glass cutting started

Back from vacation, back to work.  Using pattern-cutting shears which allow a small amount of space between the pieces, I cut out the manila folder paper pattern that was seen in the previous post.  I then organized the pieces into envelopes by glass texture and color, clear or blue in this case.

The next step is the addition of the metal jig, seen above. (Click to enlarge photo).  Each section of the jig is securely pinned into the homasote board.  The jig serves to hold the glass pieces inside the outer border until the glass pieces are foiled and tack soldered.  I use jigs in different lengths to accommodate various shapes and sizes of windows. This window is approximately 28" across.

I've already cut the outer row of clear glass, as seen above.  Its a clear rough rolled glass with a nice texture.  I'll be working my way toward the center of the octagon, cutting the glass in order, segment by segment, by type of glass. The next row will be medium blue rough rolled glass, followed by clear glue chip, then hammered clear for the larger petals, then more blue rough rolled, and a clear crystal ice center. 

The window will come to life as each area of glass is cut, grinded, and placed onto the pattern.  Stay tuned ...

Boehm Stained Glass Studio website and FaceBook site.

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!

Boehm Stained Glass Studio website and FaceBook site.