Leaded Stained Glass Custom Sailboat Window Collaboration

This project has been in the works for about 10 months.  I'm pleased to report that it was installed two weeks ago.  We had repaired a large Shamrock-themed stained glass window for a customer back in May of 2012.  See that project here. She was so impressed with our work, that she called me back at the end of last year and asked me to work with her to create a custom stained glass Christmas gift for her husband.  The subject was to be his beautiful racing sailboat. I realized that my studio would not be able to handle it due to the size .. 67" wide by 34" high.

Here at Boehm Stained Glass Studio, we always do what's best for our customers.  Since I knew this project was too large for us, I brought in a trusted colleague, an artist who works mainly with "leaded glass" as opposed to "copper foiled" or "Tiffany style" stained glass, which is my area of expertise.

"Leaded glass" can be found in older homes and is characterized by thick lead lines which are soldered only at the intersections.  It is the preferred technique to use for large pieces and for windows which are exposed to the weather.  My technique, "copper foiled" or "Tiffany style", is well suited to indoor residential windows of approximately 30" or less on all sides.  Both use similar clear or colored glass, but the techniques, expertise, and tools required differ greatly.

My role in this venture was to design the window and to coordinate the installation.  My collaborating artist did the entire fabrication at her studio.  It took several months between the initial design concept and the fabrication and installation, because we were waiting for renovation of the home to be completed.

Below is our working photo of my customer's 46' sailboat called "Testing Life".  It is a 1996 Tartan 4600 docked in South Jersey.  My Dad owned a 32' Albin Sport Fisher, so I'm very familiar with the boating lifestyle.  Even though our boat was a cabin cruiser, I had an immediate affinity for the family's love of boating. Our boat was the centerpiece of our Summers, as is theirs. Here are photos of the boat and the process to create a tribute to it in stained glass:  (Click on any photo to enlarge).

Below is the pentagon shaped window where the stained glass sailboat is to be installed.  Notice the peaceful view of the lagoon.

Here is the sailboat.  The family of five with their two dogs were on board.

Below is my design which includes each family member.  My customer and I had a few discussions specifying her wishes for the finished window.  The design below incorporated her vision of what the window would be.

This past August, my husband Eric and I came down the shore to visit our customers at their new home, take photos, and prepare the paper template, below.  Eric routinely prepares a paper template for any unusually-shaped window, to be sure of a perfect fit at installation time.  We then prepared three full-size copies of the pattern, the original template, all the measurements, other photos of the room, and a full-color rendition of the pattern above, to my collaborating artist.

Below, a photo of the window still on the work table.  Her studio did a beautiful job, using flashed glass to etch in the name of the boat and the numbers on the sails.  

In this closer-up view, (click to enlarge) the family members and their two dogs can be seen.  Colors for the dogs, hair color and baseball cap, was specially chosen to represent each member of the family.  The white deck and windows were painted on.  Some smaller areas were rendered in copper foil. The studio did a fantastic job of interpreting my design.

About two weeks ago, her crew headed down the shore and installed the window.  Here it is!  

Another view of the completed, installed window.  As a first-time collaboration, I'm very pleased with the results.  It was a joy to have my design interpreted so beautifully by a fellow artist.  My customers are equally pleased.  We hope they enjoy this tribute to their sailboat for many years to come!

To see more of my stained glass work, please visit my website (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.  Thanks!

Stained Glass custom-design cabin cruiser

This 16" x 10" panel was commissioned by a woman in Kentucky to give to a dear uncle.  Its a rendition of his cabin cruiser which I designed from an emailed photo.  See how I created this one-of-a-kind gift!  (Click on any photo to enlarge for a closer look).

Here's my customer's photograph of her uncle's gorgeous cabin cruiser.  My dad had a cabin cruiser in the Hudson River for many years, so these boats have a special place in my heart.

Here's my computer rendition of the photograph.  I sent multiple combinations of glass choices for the sky and for the water.  My customer wanted a sunset sky.  She chose this Spectrum Mimosa Pearl glass which is comprised of yellows, oranges and some white .. It was the perfect choice to complement the Spectrum Mystic Blue water.

 Here's the pattern .. The "cartoon" or original design is on top with carbon paper in the middle and Manila folder on the bottom.  All of the markings are traced directly onto the manila folder.

Below, I've cut out the patterns for the sky and then traced them onto the Mimosa Pearl sky glass.  From there, I used my Gryphon Omni Saw to cut the top right and top left piece, as they were too complicated to cut by hand.  Notice that there's a fence or "jig" pinned around the border.  This will remain in place to keep the glass pieces from shifting as they are placed on the "cartoon."  At this point, I haven't yet cut out all the pattern pieces.  When I cut them, it will be with specialized, double-bladed stained glass pattern shears.  They leave a small space between the pieces which is taken up later by copper foil.

 Now the sky, water and hull have been cut.  There are 57 pieces of glass in this panel.

Here are the stained glass pattern shears showing that small space which they cut out.

 For the area of the cabin cruiser where the railing meets the hull, there are several pieces in a row.  Since I want the panel to look as realistic as possible, I'm cutting that area from a single piece of glass as shown.  I then traced the pieces onto the glass and cut each piece in order.  In this way, the horizontal "sunset" lines are preserved.

 A handful of cut glass ready to go down.  After each piece is cut, I grind the edge with an electric, water-fed grinder.

Here I'm tracing the pattern for the length of white glass which covers the deck.  I'm using the same process as above, cutting one larger piece and then dividing it up as the pattern indicates.

Below, all of the glass is cut.  Everything is still contained inside the "jig".

Below, I'm applying self-adhesive copper foil to the edge of the glass.  Copper foil comes with three different colors inside .. Copper, silver and black.  I used black back foil for most of the piece.  In order to get the brightest white, I used silver back foil for all of the white glass.

After each piece has been foiled, I press it onto the glass using a flexible plastic wand or "fid".

Now, all of the pieces have been foiled.

As I do with all of my custom designed stained glass panels, I signed my name, month and year.  Below is the Dremel tool and the bottom piece of glass.  The signature becomes practically invisible as soon as the glass dust is rinsed off.

 Below, I'm applying Canfield Blu-Glass Flux to the copper foil using a metal acid brush.  Flux is a very caustic substance and needs careful treatment.

 Below, I've "tack-soldered" the panel with small dots of solder at the intersections of the glass pieces and at random places.  This assures that the pieces stay together in place when I remove the "jig".

I then remove the "jig" and fully solder the front of the panel.  Then I use Kwik-Clean Stained Glass Flux and Patina Remover spray on the panel and towel dry it.

And here's the front, fully soldered.

My husband Eric has measured and custom cut a sturdy zinc frame for the panel.  Here he's attaching them for me.

Seen from the back, the panel is back in the jig and the frame is in place on the border of the panel.  I then flux the corners and spots where the lead lines meet the frame.  I solder them all to provide stability and strength to the panel. Once that's done on both sides, I wash each side again and take off the jig.

Here I'm preparing the brass hanging hooks.  The one on the left has been "tinned" meaning that I applied liquid flux to it and then dotted on a bit of solder.  The one on the right has not yet been tinned.

The back right side hook is in place.

After the panel has been spray cleaned of all the flux from soldering, I allow it to dry completely.  Then, using another metal acid brush, I apply Novacan Black Patina to all the solder lines and to the zinc frame.  I work from the bottle cap so as not to contaminate the contents of the bottle.

Here the panel has been fully patina-ed and cleaned.  Next, I'll apply Liva Stained Glass Finishing Compound.  This is a light wax which serves to protect the patina and give the panel a nice shine.  Then I'll take it outdoors to get a "real life" photo of the panel in the light. 

And here's another look at the sequence .. From photograph .. To computer rendition .. To completed panel!

Thank you for having me make this special gift for your uncle, Laura! May he remember your thoughtfulness every time he looks at it. 

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!