Stained Glass Basics

Copper foil construction

Many instruction books are written and hobby classes taught on this subject.

This is a very basic overview to give you an idea of the process.

Place glass on a smooth surface.  Homosote boards are available in home stores, carpet or newspaper helps cushion the glass while you apply pressure to the cutter.  Hold a glass cutter at a right angle to the glass.  Place the glass smooth side up.  Plan a verticle cut, either pushing or pulling the cutter from one edge of the glass to the other.  Apply constant medium pressure to the score.  There will be probably be some sound, but not a loud noise as you make a successful score.  Too much pressure can cause a bad break and to little pressure will not make a score. Do not stop.  Do not rescore the line. 

You can break the score with your hands but most beginners use running pliers.  This tool has curved jaws with plastic cushions.  Notice the red line drawn to accent the engraved black line under the cushion.  Line this line up along the score you just made. 

Apply pressure to the pliers and run the score.  This should run across the glass.  If it doesn't usually you need to either rescore the glass, apply more pressure on this score.

Once the glass is all cut and fits to the pattern it is time to apply the copper foil.  The sticky underside of the foil is protected by a piece of paper.  You need to remove the paper from a section of foil to place it on the glass.

Wrap the foil around each piece of glass.  Center the glass down the piece of foil.  Press the extra foil down on either side of the glass and burnish it with a marker or fid (tool used for burnishing foil). 

A light coating of flux is needed to prepare the solder to run and stick to the foil.

Solder is used to wrap around each piece of glass and hold the project together.  It will not stick to the glass without foil or other adhesive.  Heat the end of the solder and run the iron along the foil you want to solder.  You want a nice even seam with some height for strength.

Finished and framed.