Stained Glass Commemorative Gift

Stained glass panels make wonderful, personal gifts.  My customer asked me to create this commemorative anniversary panel from artwork which was admired by someone special in her life.  I submitted several variations of the design as well as different color combinations. Here's the one which was the winner!

It's based on the color wheel and has some nice, clear textured glass in the center areas. It's 13" round.

I created a pattern by tracing the shape and markings onto Manila folders, using carbon paper.  Here I'm using special double-bladed pattern shears to cut out the individual pieces.  The shears leave a narrow strip between the pieces which allows room for the copper foil which will be added later.

Here's the colorful palette of wispy and streaky glass that I've chosen for the gift.

Here's a close up showing texture of the clear granite glass for the center areas.

Resting the oil-filled pistol grip glass cutter on a ruler (which I hold down with my right hand).  This enables me to make straight cuts.

After repeatedly tapping, front and back, on the score made by the cutter, the glass will eventually separate.

These "groziers" are used for nipping off small bits of glass.  The blue tool are my "running pliers" which are used to snap straight scores/

After each piece is cut, it goes to the electric grinder.

As the pieces are cut, I organize the pattern pieces into junk mail envelopes.

A few pieces of the yellow, traced onto the glass and ready to be cut.  For this project, I chose a variety of types of glass, most with variations in color on each piece.  This adds to the interest and also makes for a better transition from color to color.

Using the running pliers to snap a straight score.

Now the first few colors are cut and ready to be placed on the "cartoon" or original paper pattern,

Here all of the glass has been cut and is in place on the pattern.

Now I'm applying 7/32" copper foil around the border of each piece of glass.

Using a "fid" or flat plastic want to burnish the foil onto the glass.

Some of the pieces have been foiled.

All of the pieces have been foiled.  I used push pins to lock them into the work surface so that they don't shift as I flux and solder them,

Brushing liquid flux onto the copper foil.  This chemical allows the solder to flow freely over the foil.

Here I'm doing the "tack soldering" process whereby I'm locking together the pieces of glass with small amounts of solder.

After the pieces are locked, I remove the push pins and slide the cartoon out from underneath.

Then I fully solder the front of the panel.  After soldering is complete, I spray it with a chemical neutralizer and buff it off.

Now the design has been fully soldered, front and back. I'm now fitting a length of lead came around the border, to create a frame for it.

As I fit the frame around the border, I'm soldering it to the lead lines around the perimeter.

Since this piece will be hung on a wall or in front of a window, I'm hand-crafting hanging hooks.  I'm using 20 gauge copper wire wrapped around a metal acid brush.  I leave long tails on the hooks for maximum bonding to the frame,

I've soldered the "legs" of the hooks directly into the lead lines.

Black patina is a chemical which instantly turns the solder black.  After its allowed to set, I wash it off using the neutralizing spray.

Here's the panel right after its been patina-ed and before its dry.

Finished!  This view is in front of a white wall.

And here it is, front lighted and back lighted.

Another view outdoors, showing the colors.

One more view out doors.  Thank you Beth for asking me to make this special gift!  I was thrilled to hear how well it was received.

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

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Custom Recognition Gift in Stained Glass

Recently I was asked to create a very special, one of a kind gift to commemorate and recognize a former resident's many contributions to the Borough of Essex Fells, NJ.  My customer and I had a brainstorming session over the phone and we collaborated to design this unique commemorative plaque for him.

Here is the design which features a border of medium blue rough rolled Cathedral glass.  Inside the border are 8 clear bevels which add elegance to the plaque.  The center piece was originally rendered using white opal glass, but I later decided to change that to white and clear wispy.  We both agreed this was a nicer choice.  Permission was granted for the use of the borough's logo which serves as the centerpiece.  The overall size is 11" x 11" square .. Perfect to set on a desk with the sun streaming through.

This plaque involved very little glass cutting .. Just the four blue border pieces and the center.  Here I'm in the process of creating a template for the blue corner pieces.  I'm using Manila file paper with carbon paper as shown.

Here are the bevels and the 9" x 9" center piece which is white and clear wispy glass.

I cut the blue border glass on an angle to the Rough Rolled glass, to add more textural interest to the plaque.  

Here I'm using an oil-filled pistol grip cutter pressed against a flat ruler to score the lines. To break the scores, I tapped repeatedly on the glass, front and back along the scores, until the glass "loosened" and separated.  

After the blue border pieces were cut, I brought them to the electric grinder.  I used this to grind down the edges of the glass.  This makes it safer to handle and allows the copper foil to adhere better.

 

Next, I apply 7/32" adhesive copper foil to the edges of each piece of glass.  I'm using "black backed" foil because I'm using bevels.  The interior of the foil will show through the bevels.  As soon as I've applied the black patina, the interior of the foil becomes invisible.

 

Here I've enlisted the help of my artistic husband Eric who used a light box and friskit to mask the Essex Fells logo.  He painted the logo using black glass paint.  After the logo was painted, we waited the requisite 24 hours for it to cure.

 

After 24 hours, I baked the glass and logo in a 325 degree oven for 40 minutes.  This makes the paint permanent on the glass.

Here is the center panel in place with the bevels and medium blue border.  After the center piece cooled, I applied copper foil to it.  I added four "fences" or "jigs" to the sides to keep the plaque square.

  
 Now Eric uses his band saw to custom cut a metal frame.  He also started working on the custom desk stand while I began the soldering process.

Now the plaque is soldered on the front and back ..

And now the metal frame has been added. After the soldering and framing, I give the plaque a thorough cleaning.

Here I'm applying Black Patina to the metal with an acid brush.  The patina turns the metal black instantly.  I let it set for several minutes, then I clean off the excess and allow it to dry completely.  After it dries, I apply stained glass finishing compound.  This is a light wax which protects the patina and gives the glass a nice shine.

And here is the finished plaque!  I think it makes a very fitting and thoughtful gift for this gentleman who gave so many years of faithful service to his town.

And here's the plaque in its custom desk stand.  The beauty of the white and clear wispy glass can how be seen, and the bevels add a nice touch, too.

Thanks so much, Susan, for calling upon me to design and create this very special recognition gift for a very deserving individual!  It was my pleasure!

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

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Mini Rainbow Stained Glass Church Window

Stained glass panels make wonderful gifts.  I was recently asked to create a window as a retirement gift for the organist of a local church.  After serving for 30 years, her choir and congregants wanted to have something special made for her.  In just three days' time, here is what I made for her .. Click on any photo to enlarge.

Here is the beautiful, full size window in the church.  It's breathtaking!

I worked from a photograph of the window and decided to use one area of it, below, and change the colors to reflect the colors within the large window.  The panel I'm creating is 10" wide and 13" high.

Here are samples of the glass I used for the project, which I donated to the church.   I made the panel using all Cathedral glass which I had in stock.  Cathedral is colored clear glass which lets the most light through, as opposed to opalescent glass which is denser and lets in less light.  There are many variations in between.  I chose colors which are deeply saturated to give a beautiful rainbow effect.

 Here is a computer-generated rendition of the finished window which was approved by my customer.  We made a few changes based on her requests, which is easy to do. 

 An early step in the process is the preparation of the pattern.  Below, I've taped Manila folders, edge to edge, overlaid carbon paper sheets, and then added the numbered pattern on top of that.  All three layers are then anchored to my work surface which is a wood table covered with a sheet of Homasote.  That's a fire-resistant, spongy sound proofing material which accepts push pins readily.

 After the pattern has been completely traced, I cut out the external border using regular scissors.  For the pieces themselves though, I use specialized stained glass pattern shears.  They are double bladed and cut out a small channel between each piece as shown below.  This small channel will be taken up by the thin copper foil which will follow later.

 Then the glass cutting begins.  I cut out portions of the total pattern, one color at a time.  Here I've traced the yellow pieces onto the glass with a Sharpie marker.

 Then I use an oil-filled pistol grip glass cutter at a 90 degree angle and score the glass at the edges.  Then I'll use either the black-handled groziers (on the left) to snap off the glass, or I'll use the blue running pliers if the score is longer and straight.

 After several pieces have been cut, I take them to the grinder for the edges to be smoothed out.  This makes the adhesive copper foil adhere much better, and it also makes the glass safer to handle.  Notice that I'm wearing "rubber fingers" as I handle the glass.

 Here's a piece of the streaky white glass being snapped along the score line with the running pliers.

 Here's the panel with all of the glass cut.  Notice that I've placed a "fence" or "jig" around the panel.  This serves to keep it square and prevents the pieces from shifting around as they're placed on top of the pattern.

 After all the glass is cut, I begin applying adhesive copper foil to the edges of each piece of glass.  For this project, I wanted thinner solder lines so I used 13/64" foil instead of the standard 7/32". 

 As each piece is foiled, I use a "fid" or flexible plastic wand to smooth down the edges and press it into the glass.  This prevents chemicals and liquids from seeping under the foil.

 Here's the panel with the copper foil process completed.

 Next, I apply Canfield Blu-Glass Flux to all the foil on one side, using a metal acid brush.  I work with flux out of the jar cap and dispose of any unused flux, so as not to contaminate the contents of the bottle. 

 Here I'm doing the "tack soldering".  I'm adding small dots of solder to the intersections of the glass pieces.  I'm soldering just enough to keep the pieces attached to one another.

 When the tack soldering is complete, I release the fence and slide the "cartoon" or pattern out from underneath the panel.  This is to protect it from the chemicals and cleaning solutions which will follow. Once the panel is off the cartoon, I go back and fully solder the front.  Then I turn the panel over and fully solder the back.

Here's the panel on my light box. Love the colors!

 My husband, Eric, custom makes all the metal frames and stands.  Here he's taking measurements.  After he attaches the frame around the perimeter, he put the fence back on it.  Then I solder the corners and the lead lines to the frame for stability and strength.

 Once the panel has been framed and fully soldered, I add my signature and date using an etching bit in a Dremel tool.  After the dust has been cleared from the etching, its barely visible.

 My customer requested that the piece be created with a stand, so here's Eric preparing it using poplar wood and metal fittings.

 Here's a photo of the panel, fully soldered, framed and cleaned.

 The next step is the patina process.  Here I'm using a different metal acid brush to apply Novacan Black Patina, which reacts instantly with the solder.  I coat both sides and the frame with the solution.

 After the panel is patina-ed, I clean it using Kwik-Clean Stained Glass Flux and Patina Cleaner.

 And here is the finished panel!  This was photographed with the panel against a white wall ...

 .. And here is a photo of the panel taken on a light box.  As with all stained glass, it will look different under different lighting conditions.

And here's the panel in its custom-made stand, in the sunlight which casts a beautiful reflection.

it is my hope that the organist will look at this and remember her many years of playing, as well as the thoughtful parishioners who arranged to have such a thoughtful gift created for her.  Thank you Gail and Robin for finding me!  It was a pleasure!

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!