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