How to Make a Wine Bottle Stained Glass Panel

Incorporate wine bottles into a stained glass panel to create a beautiful display.
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Materials and Tools:

4 wine bottles
flat glass sheets of various colors
glass nuggets
copper foil tape
solder and soldering iron
brass edging
glass grinder
glass scorer
glass-breaking pliers
flux in a spray bottle
burnisher
paper leaf template
permanent marker
ring saw
ear protection
straight pins
ceiling tile
light table
container of ice water
propane torch
straightedge
bottle cutter
glass cleaner and cloths
power saw
safety glasses

Steps:

1. Draw a design incorporating wine-bottle bottoms and depictions of a wine bottle, a wine glass, a grape cluster, a cheese wedge and a table.

2. Score the wine bottles around the bottom with a bottle cutter to remove the bottoms.

3. Heat the bottles along the score lines with a propane torch.

4. Dunk the hot bottle bottoms in an ice bath. The bottoms should break off. If they don't break the first time, repeat the heating and cooling steps.

5. Smooth the edges of the bottle bottoms on the grinder.

6. With a scorer and breaking pliers, cut flat glass pieces for the panel from colored glass according to the design.

7. Trace a grape leaf from a paper leaf template onto a piece of green glass.

8. Score and break the green glass to form the rough leaf shape. Cut out the detail on a ring saw. Grind the edges. Wrap the edges with copper foil tape and burnish.

9. Wrap the edges of the glass nuggets for the grape cluster. Form the grape cluster on a ceiling tile and hold the design in place with straight pins.

10. Place the drawing on a light box. Place a clear glass sheet on the drawing, and mark the pieces to be cut with a permanent marker.

11. Score the glass and break the pieces. Place the pieces on the drawing for fitting.

12. Fit the wine-bottle bottoms and flat pieces on the panel drawing. Grind and re-grind the pieces to fit the drawing exactly.

13. Cut the corners of the rough pieces so that the punts (the raised portions) of the wine-bottle bottoms can fit through them and the bottom can rest on the flat glass. Mark the flat glass around the bottom. Cut and grind the glass to fit against the bottom.

14. Wrap the edges of the bottoms and all glass pieces in copper foil tape. Burnish the copper on all the glass pieces.

15. Arrange all the wrapped pieces on the design, apply flux to the seams and solder the copper foil edges with a soldering iron and solder.

16. Cut the glass pieces for the border, arching the top and adding different-colored glass pieces at the corners. Apply copper foil tape to the edges and burnish the tape to the glass.

17. Apply flux and solder the border to the designed glass piece.

18. Cut the brass edging with an electric saw and solder it to the panel.

19. Clean the stained-glass panel with glass cleaner and polish it with a cloth.

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