Technical

How its made:

There are 2 methods to making the stained glass you know and love; The Tiffany Copper Foil Method and Lead Came method. 

I use both methods in my pieces, with the Method I choose being dependant on several factors such as design complexity and project type. 

Tiffany Copper Foil Method:

The traditional Tiffany Copper Foil Method is used for complex designs, lamps or 3d pieces, and pieces that won't be subject to harsh weather. It is more fragile than the traditional Lead Came Method, but can create a lot more detailed pieces. 

The Process:

  • Once a pattern has been decided upon and enlarged, glass is laid on top of the pattern and cut to a rough size and shape
  • Once all the pieces have been cut they are taken to a grinder to be ground to the perfect size and shape. They must fit together perfectly to create a neat and uniform final product. 
  • Once this step is complete, copper foil tape is applied to all edges of each piece. This step is crucial as solder will not stick glass alone and needs the copper to adhere to. 
  • The foiled pieces are then taped together in accordance to the pattern and soldered. The piece is then cleaned of all flux and residue before applying polish, patina (a liquid that changes the colour of the solder from silver to black or copper) and wax. 
  • Tiffanny Copper panels can either be hung as a window or wall hangings or be made into sealed units.

Lead Came Method:

The traditional Lead Came Method is used for simpler designs, windows or pieces that will be subject to harsh weather.

It is stronger than the Tiffany Copper Foil Method and can be completely weatherproofed and watertight 

The Process:

  • Similarly to the Tiffany Copper Foil Method, to start a lead came project a pattern is decided upon and enlarged. The glass is then laid on top of the pattern and cut to a rough size and shape, leaving room for the lead strips. 
  • Narrow, flexible strips of lead, called "lead came," are then used to hold the glass pieces together. 
  • Once the panel is assembled, solder is used to join the glass together. The piece is then cleaned of all flux and residue.
  • Interior and exterior panels are puttied for strength, and then a finish (patina) applied to the lead and solder.
  • Stained glass panels to be made into sealed units are now ready for the finish (patina) to be applied to the lead and solder. 

Installation Methods for Windows

Thermal Triple Paned Sealed Units:

Making the stained glass panels into a triple paned sealed unit has many practical applications.

By sandwiching the stained glass panels with tempered glass, which is 8 times stronger than normal glass, you have a very structurally sound unit that resists breakage and meets all building, safety and NFAS codes.

The stained glass panel is not ravaged and weaken by the weather, and is very easy to clean!

Stained Glass Over Dual Sealed Unit:

Stained Glass may also be installed on the inside of an existing dual or triple paned sealed window. The stained glass panel would need to be spaced away from the window by a wood spacer, and then held in place with a wood stop. Alternatively I can add hooks and a chain to hang in front of the window.