| We recently repaired and replaced a leaded glass | | | | the pattern I traced earlier, so I could make sure |
| panel. This was a repair to a leaded window and | | | | the window stayed the right size.14. Then I slid |
| we traditionally use the copper foil method | | | | both of the replacement pieces of glass into the |
| developed by Tiffany studios in the early 1900's. | | | | lead came.15. I tapped them into place tightly using |
| So we were mixing two styles of glass | | | | gentle pressure from a glass hammer.16. Then I |
| construction. The results were perfect.1. A client | | | | nailed the outside lead, in place making sure that |
| called and asked us to repair a window in their | | | | the glass was tight and inside the lines of the |
| home. The window had a broken piece of glass | | | | pattern.17. Up until this step, the techniques I used |
| and we would need to take it from their home, | | | | are those that both a copper foil artist and a lead |
| repair it at our shop and reinstall it in their | | | | artist would use. From this point on, I focused on |
| entryway.2. The window frame had been | | | | copper foil methods. I placed a strip of copper foil |
| assembled with 45 degree miters in the wood, | | | | along the bottom of the panel, so there would be |
| which required that the nails be removed in order | | | | something to solder to. We might have used lead |
| to get the wood out. Fortunately, the nails used | | | | came but the came we had in stock didn't match |
| were very thin pin nails, similar to a staple in size, | | | | the original lead.18. I foiled the bottom three |
| so I was able to break the fasteners with a sharp | | | | beveled pieces with copper foil, getting ready for |
| rap on a putty knife at each nail.3. Once all the pin | | | | soldering the panel.19. I cut a piece of zinc to fit |
| nails were cut, I was able to carefully remove the | | | | the panel and nailed it in place, making sure that |
| wood from the frame work.4. The leaded panel | | | | the panel still fit inside the penciled in pattern.20. I |
| was very tight in the framework, which is rare, | | | | carefully soldered the joints at the bottom of the |
| and I had to gently work the panel loose so as | | | | panel, using care to only heat the lead that was |
| not to break it. This installation had one piece of | | | | being attached just enough to solder to, trying to |
| tempered glass on the outside of the door frame | | | | avoid melting the came.21. When the solder lines |
| and then the art glass. In our studio we insulate | | | | were complete, they were a little too shiny to |
| window units so that there is tempered glass on | | | | match the original window, so I cleaned it with an |
| each side of the art glass.5. Because the | | | | ammonia based cleaner which darkened it and |
| tempered glass was still in place, I simply replaced | | | | then added a dilute black patina to knock the color |
| the wood pieces back in the frame till the reinstall | | | | down.22. After polishing and waxing the window, it |
| took place. Normally we put a piece of cardboard | | | | matched the original pretty well.23. When we |
| or plastic in the opening while it awaits | | | | went back to the home for the install, my wife, |
| replacement.6. When I got the panel back to our | | | | Jeanne wiped the window down for a final cleaning |
| studio, I first traced the outline of the panel. I | | | | to get rid of any dust and smudges.24. I |
| knew that since this window was so tight, I had | | | | removed the molding that was in temporarily and |
| to be absolutely sure that it didn't grow on me in | | | | a couple of nails from the frame work. Then I |
| the repair process.7. I heated the joints of solder | | | | followed Jeanne's example and polished the inside |
| and, using pliers, rocked the outer bar back and | | | | of the tempered glass to get rid of any dust that |
| forth until the outside strip of zinc came loose | | | | might have collected.25. I used my putty knife as |
| from the panel.8. Using a razor blade knife, I | | | | a lever to center the window in the opening.26. |
| loosened the cement joint between the lead and | | | | Then I applied a small bead of silicone caulk |
| the glass so that I could remove the glass | | | | around the entire framework.27. I gently tapped |
| pieces.9. Once the cement was loose from the | | | | the wood back in place.28. Then, since I wasn't |
| glass, I was able to de-solder the joints and work | | | | going to nail the trim back in place, I forced a |
| the lead free from the glass.10. Next, I applied | | | | stick in the opening between the molding so that |
| clear tape to both of the broken sides of the | | | | they'd be held tightly while the silicon dried. The |
| glass so that as I eased it out of the panel, it | | | | silicon will form a good enough bond to hold both |
| would stay in one piece which I could use as a | | | | the window and the molding in place.Just a few |
| pattern for the new replacement glass.11. Once I | | | | simple steps later, we had the job done with very |
| had the cement and glass loose from each other, | | | | satisfactory results.David Gomm started building |
| I applied gentle pressure on the glass and spread | | | | stained glass windows professionally back in 1983 |
| it apart so it was easy to remove from the | | | | and has become an expert at many aspects of |
| panel.12. I used the removed piece of glass as a | | | | stained glass building, design and repair. He writes |
| template to cut my replacement pieces. Since the | | | | a monthly newsletter at also has a website with |
| glass was a close match, but not quite perfect, I | | | | many other articles at articles may be distributed |
| replaced both of the pieces so that they both | | | | freely on your website and in your ezines, as long |
| looked the same. Your eye would notice the | | | | as the entire article, copyright notice, links and this |
| difference if only one of the pieces was replaced, | | | | resource box are unchanged, or if using a portion |
| but couldn't see the small difference since both | | | | of the article, it points back to one of our pages |
| were replaced.13. Next, I nailed down the panel on | | | | where the entire article resides. |