Stained Glass and Copper Amber Panel
Robin Paul welds a stained glass and copper amber panel.
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amber colored textured sheet glass cut to approx. 3-1/4" x 18"
12" x 12" sheet copper to cut copper leaves
copper tubing 1/2" x 10' length, cut two 4-1/2" lengths and one 33-1/2" length
2 copper 1/2" end caps
2 copper 1/2" elbows
2 copper pipe hangers
2 copper wires 16-gauge or larger
12" decorative chain
2 screw eyes for hangers
2 brass welding rods 1/8" x 33"
60/40 stained glass solder (use for welding and stained glass)
copper stained glass foil tape
copper colored solder patina
clear spray lacquer for metal
pliers with wire cutter
propane or MAPP gas torch
scissors or pinking shears
measuring tape, ruler, black permanent marker, cleaning rag
white wax pencil
rubber shelf gripper
2 pieces scrap wood
household sponge and paper towels
1. Secure 1/2-inch copper pipe in a vise, measure and cut one piece 33 inches and two pieces 4-1/2 inches to form the copper frame.
2. Place a copper elbow on each end of the 33-inch piece of pipe and place each 4-1/2-inch pipe in the other end of each elbow.
3. Apply flux to the joints and solder the elbows onto the pipes using a propane torch and solder.
4. Place a copper end cap on the ends of both 4-1/2-inch pieces of pipe, apply flux and solder the end caps onto the pipe. This completes the frame.
5. Place one of the 4-1/2-inch pieces of pipe in the vise with the inside of the frame facing up. Use a nail punch and hammer to punch two starter holes (image) in the pipe 1/2 inch from the end cap and 1/2 inch from the elbow for drilling the holes for the rods to hold the glass.
6. Drill the two holes using a power drill. Turn the frame over and place the other 4-1/2-inch piece of pipe in the vise and drill two more holes the same as the ones in the first pipe.
7. Cut two pieces of 1/8" x 33" brass welding rod. Position them in the drilled holes between the two 4-1/2-inch pipes, flux and solder the rods into the holes.
8. Clean the copper pipes and welding rods with steel wool.
9. Using a ruler and a white wax pencil, measure a 3-1/4" x 18" piece of amber textured glass. Place a piece of rubber shelf gripper under the ruler along the measured line and score the glass with a glasscutter. The shelf gripper prevents the ruler from shifting on the glass. Break away the scored glass piece.
10. Apply copper foil to the edges of the glass. Burnish the copper foil with a small wood stick.
11. Apply flux to the copper foil. Tin the copper foil by applying solder over the foil using a soldering iron.
12. Place the glass on a piece of scrap wood and position the frame on top so the glass is between the welding rods. The scrap wood will raise the glass to the height of the welding rods.
13. Apply flux to edges of the glass and the welding rods and solder the glass to the welding rods.
14. Place silk leaves on top of copper sheeting, trace around them with a wood stylus and cut leaves out using pinking shears. Cut a total of four leaves.
15. Cut two pieces of copper wire and solder a copper leaf on each end.
16. Place one wire with the leaf ends around the welding rods above the glass panel, curling the wire decoratively and solder it to the rods. Solder the other wire to the welding rods below the glass panel.
17. Wrap a wet household sponge with a wet paper towel. Place the sponge under one of the welding rods and apply a large blob of solder onto the rod and onto the sponge. Let the solder harden.
19. Attach two copper pipe hangers to the top pipe.
20. Apply patina solution to all the soldered areas and let it set.
21. Spray the metal parts with clear lacquer. Let dry.
22. Hang the stained glass and copper amber panel from two screw eyes secured to a window.
Robin Paul of Des Moines, Iowa, took her parents' advice and pursued a degree and career in business. Yet she could not ignore her creative side, and in her spare time she dabbled in drawing and painting. It wasn't until she discovered metal and glass, though, that she experienced true artistic fulfillment. She realized it was the first time she could conceive a project in her head and actually execute it to her satisfaction. Now her projects far exceed everyone's expectations with her non-traditional metal and stained glass window panels.
Keri Plezia from Wickenburg, Ariz., uses colorful glass nuggets to create a unique picture frame.