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.

Blue Jay and Nuthatch stained glass panels installed

I prepared these 6" x 11" bird panels for installation the same way as the Cardinal completed last week. I soldered on 4 small brass clips, 2 on each side of each panel, as shown below.  These clips slid underneath the mullions on the back door.

Since this project was a "fill in" job started in April, the solder had oxidized a bit, so I needed to go over it with steel wool #0 in order to prep it for the black patina.  That done, I waxed and polished each panel.

Eric unscrewed the lower portions of the mullion and then we lifted it up and positioned the birds underneath, catching the brass clips as we went. They are securely locked in now.  To see the entire process which I repeated for each of the three birds, click here.  (Click on any photo to enlarge).

These birds add new life to the back door!  I'll be happy to make a custom door panel for you in any theme or color.  Call 201-600-1616.

Today I started the design process for a new commission, a 29" octagonal window.  Stay tuned ...

Click here for Boehm Stained Glass Studio website (and if you will, please "like" our new FaceBook page). Thanks!

Stained Glass Cardinal complete and installed

This Cardinal was a "fill in" project started back in April.  Please click here to see the Cardinal and two other birds started then.  I created each of them to fill in a few of the nine 6-1/4" x 11" glass panels in our back door. (Click to enlarge any photo).

Eric cut 4 small brass tabs which I soldered onto the back of the piece as shown below.  I used square balsa wood sticks to rest the tabs on during soldering.

Below is the front of the panel with the tabs soldered.  Its been patina-ed black. These panels feature clear textured autumn leaves glass from Delphi.  Its a thick glass that adds dimension and privacy yet allows light to shine through.  The brilliant orange-red is a wispy glass which I cut to show the movement of feathers.

I always use a partially clear glass for birds' and animals' eyes.  In this case, I used black-on-clear Baroque glass to add life to the piece.

 

And here it is!  To install this panel, Eric partially removed the mullions and slipped the panel underneath the center window, making sure to catch the tabs underneath.  Worked like a charm! 

Do you have this type of door?  If so, I would be happy to create custom panels to add color and character to your home.  Give me a call at 201-600-1616 and inquire.

Upcoming will be two more birds to join the Cardinal. (Or the designing of the octagonal window project, whichever comes first).

Click here for Boehm Stained Glass Studio website.

Stained glass cabinet panel completed

Another window completed!  This was a different challenge, to duplicate an existing window.  The one on the left is the original.  The one on the right is my copy, 1" wider.  (Click photo to enlarge).

 

A lovely note of thanks from my happy customer!

Dear Kath,
I was so so excited when I saw the finished product of my stained glass door insert! You did such an incredible job of matching the other panels -- now my kitchen matches again. I loved watching the progress of the workmanship on your blog. Please thank Eric for me for hanging everything back up. And thank you, Kath, for such beautiful craftsmanship... I am so pleased!
Kathi

Thank you Kathi!  It was a pleasure meeting you and restoring your kitchen panel. I hope you will enjoy it for many, many years to come!

Next project: An octagonal interior window.  The design process will be underway shortly.

Click here for Boehm Stained Glass Studio website.

Stained glass cabinet panel soldered

As of this morning, the panel has been tack soldered, the jig removed, and the pattern slid out.  The panel was then fully soldered front and back and strengthened with the addition of a thin metal "channel" frame around the perimeter. (Click to enlarge photo).

The original window which I duplicated did not have this frame but I made an allowance for it when I prepared the pattern because the frame gives the piece more strength and stability.  It is very thin, about the same width as a lead line, so it will be hidden under the cabinet mount.  With the added strength of this frame, it can be taken out of the cabinet and used elsewhere.

Tomorrow afternoon will be the "big reveal" .. A side-by-side photograph of the original window beside the duplicate.  See if you can tell the difference.  Stay tuned.

Click here for Boehm Stained Glass Studio website.