Things You'll Need:
- glass
- needle nose pliers
- glass grinder
- glass cutter
- cutter oil
- paper with design for stained glass
- Sharpie marker
- soldering iron
- solder
- copper foil
- flux
- flux brush
- running pliers
- grozing/breaking pliers
- safety glasses
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Step 1
Pick a pattern for the stained glass you would like to create. If you are just starting out pick a simple design. Any curves or small pieces add difficulty to the project. You can use a template or create one from a picture or artwork that you already possess. Make a copy of the original template to assist with assembling all the glass pieces
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Step 2
Cut out the pieces from your template. Numbering the pieces on the intact and cut out pieces will make assembling the final product much easier (and less of a jig saw puzzle).
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Step 3
Once you have decided what color glass will go in which spots its time to start transferring the pattern onto the glass. Start by laying the cut pieces on top of the glass and tracing the piece with a Sharpie marker. You can place the transfer outline anywhere on the sheet of glass but I prefer to transfer them to the end to save time, energy, money, and peace of mind.
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Step 4
Remove the section of glass that has the transferred pattern. This will make it easier to cut out. Remove the glass by scoring the glass, use the glass cutter, making one line on the glass, from one end to another end, to remove the section where the pattern is located. Any cut you make on the glass should go from one side of the glass to another side of the glass. To break this piece off place the score between your thumbs with index fingers curled underneath the glass. Gently apply pressure with your index fingers to break the score apart.
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Step 5
One side at a time score the glass and remove the excess until the desired shape is removed. As the pieces of glass being removed get smaller using the various pliers will be a hand saving tool. The needle nose pliers can be used to remove small pieces of the glass while the larger pliers can be used to remove larger pieces. With the larger pliers ensure that the flat side is on top of the glass and use your other hand placed as closely to the score as possible.
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Step 6
Use the sand grinder to smooth out the edges of all the pieces that you have cut. Consult your grinder manual for specifics on how to use this machinery. Unfortunately using sand paper by hand does not produce the same results, the smoothest surface is important to allowing the pieces to properly align together.
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Step 7
Once the pieces have been smoothed and dried it is time to ensure that the pieces fit properly. By putting together the puzzle before continuing you can adjust any pieces that may have been cut too big, or if you so desire re-cut pieces that ended up too small. Completing stained glass is an art and takes lots of experience to end up with a perfect result.
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Step 8
Once you are satisfied with you cut and assembled pieces you need to wrap the edges in foil. Double check before applying the foil that it is straight and evenly balanced on the front and back of the glass. This is what the solder will adhere to in order to fasten the pieces together. Smoothly press down on the foil to ensure it is securely fastened to each piece. If some pieces are too small when you lay the puzzle together you can crumble up some foil and insert in within the gaps to allow something for the solder to grab onto.
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Step 9
Almost there, fire up the solder and get ready for the finishing steps. Apply small amounts of flux to the foil edges that are exposed and apply the solder in small sections to adhere the pieces together. Soldering itself is another art form and may take some practice to form the desired smooth surface.
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Step 10
If your artwork is square you make choose to have use a lead frame. If this is the case cut the lead framing pieces to size, insert them in place, apply flux to the junctions and solder the pieces together. If you would rather you can always use the solder material to frame the remaining exposed copper foil and produce a finished appearance. Wire hooks may be soldered in at this point if you wish to hang your artwork.
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Step 11
Now that the stained glass is assembled and held together all that's left to do is clean it. Using a soft rag with mild, non abrasive soap gently wash your artwork.
