Stained and Fused Glass Panel

Use these step-by-step instructions to create a stained and fused glass panel.
hclvr260_1final

hclvr260_1final

Stained and Fused Glass Panel by Mary Datwyler from Rio Rancho, N.M.

Materials and Tools:

stained glass
7/32" copper foil (choose black or copper back depending on patina color)
black or copper patina
liquid polish for stained glass
50/50 (lead/tin) solder and soldering iron
gel flux
handcrafted dichroic glass fused cabochon
copper U-channel
pencil and paper
pistol grip glasscutter
glass pliers
glass grinder
ceiling tile
Morton Layout Block system
needle nose pliers
cotton cloth
paintbrush
rubber cement
fid burnisher
rubber gloves and safety glasses
2 jump rings and chain
wire cutters

Steps:

hclvr260_1b

hclvr260_1b

1. Sketch a design for the stained glass window onto paper, leaving a space in the center for the handcrafted cabochon.

2. Number the pieces and assign pieces to pre-selected colors of glass.

3. Cut the paper pattern apart with scissors.

hclvr260_1c

hclvr260_1c

4. Affix the individual paper pattern pieces to colored glass with rubber cement.

5. Wear safety glasses. With a glass cutter, cut the glass pieces following the pattern piece outlines.

hclvr260_1e

hclvr260_1e

6. Grind the edges of the glass pieces on a glass grinder.

7. Remove the paper patterns. Clean each glass piece.

hclvr260_1f

hclvr260_1f

8. Apply copper foil to the edges of all glass pieces and burnish the foil with a fid burnisher.

hclvr260_1g

hclvr260_1g

9. Grind the edges of the cabochon to fit into the panel.

10. Apply copper foil to the fused glass cabochon.

11. Layout all the pieces on a ceiling tile using the Morton Layout Block system into the original stained glass window pattern. Double-check the fit of the individual pieces.

hclvr260_1i

hclvr260_1i

12. Heat the soldering iron. Apply flux to the copper foil on the front side of the piece. Solder the piece together.

13. Flip the project over. Apply flux to the copper foil on the back side. Solder the back together. Flip the piece over and insert the cabochon in the center and solder in place.

hclvr260_1j

hclvr260_1j

14. Connect copper U-channel to the edges to frame the piece. Cut two vertical U-channel pieces at each corner and bend down to miter the corners.

hclvr260_1k

hclvr260_1k

15. Pinch the U-channel together at each corner with needle nose pliers. Cut the U-channel off when the entire panel is enclosed.

16. Apply flux to the U-channel. Solder the U-channel to the glass panel for a uniform appearance.

hclvr260_1m

hclvr260_1m

17. Add jump rings to the top corners for hanging the stained glass piece. Hold the rings with needle nose pliers and solder the rings onto the top corners of the frame. Clean the completed glass panel with water and a dry cloth.

18. Wearing rubber gloves, apply the patina to the soldered areas. Rinse with water. Apply liquid polish and let dry.

19. Hand polish and buff to a finish with a cotton cloth.

20. Attach the chain to the stained and fused glass panel and hang.

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