How to Repair Leaded Door Glass
Leaded glass uses lead came rather than copper foil, and is available in an H shape. The glass fits into the channels formed by the top and bottom of the H. The replacement pieces must take into account the 1/16-inch thickness of the "heart" of the H. Experience with cutting glass and soldering will help you to repair leaded door glass.
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Things You'll Need
- Screwdriver
- Paper
- Pencil
- Replacement glass
- Marker
- Glass cutter
- Glassworking pliers--grozing pliers,breaking pliers and running pliers
- Stained glass grinder
- Lead came
- Lead knife or lead nippers
- Solder
- Soldering iron
- Temperature controller/rheostat for soldering iron
- Flux
- Stained glass putty
- Putty knife
- Whiting powder
- Nylon bristle brush
- Natural bristle brush
- Nail or toothpick
- Dust mask
- Safety glasses
- Disposable latex or nitrile gloves
- Glass cleaner
- Cleaning cloths or paper towels
Instructions
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Glass Removal
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1
Remove the window from the door.
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2
Trace the pattern of the glass being replaced.
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3
Decide the best path to use to remove the pieces. You will melt the solder and separate the lead came to get access to the broken piece.
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4
Melt the solder at the joints and remove the broken glass and any lead came that is in poor condition.
Glass Replacement
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5
Stretch the strip of lead came to straighten and stiffen it.
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6
Trace the pattern onto the replacement glass with a marker.
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7
Score each line with the glass cutter and break it with one of the glassworking pliers.
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8
Fit the new glass into the channel on the lead came. Secure the came in place if needed with a nail or tack.
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9
Cut new strips of lead came to replaced the damage using a lead knife or lead nippers. Fit the pieces snugly and cut the lead at angles where necessary. Tap into place with glazing nails.
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10
Solder the joints on both sides of the window.
Finishing
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11
Clean the window and let it dry.
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12
Secure the window in place.
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13
Use gloved fingers or putty knife to press the putty underneath the edges of the lead came.
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14
Pack the putty under the lead came by brushing against the edge of the lead came, with the nylon brush.
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15
Sprinkle whiting powder over the window.
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16
Use the brush to work the whiting powder into the putty. Scrub the putty off the glass and came in small circles. When the putty is mostly dried, vacuum up the remaining powder and putty granules.
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17
Clean along all the putty that may have oozed out from under the edges of the came with a nail or toothpick. Brush or vacuum the picked putty gently off.
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18
Allow the putty to dry for at least a few hours, turn the window over, and repeat steps 2 through 7.
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19
Allow the window to dry for 24 hours, repeat step 7 and do a final cleaning.
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20
Scrub the window gently with the natural brush to darken the lead and joints, cleaning off any remaining putty.
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21
Clean using glass cleaner and cloths or paper towels and return the repaired window to the door.
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1
Tips & Warnings
Use safety glasses.
Do not eat, drink, or touch your mouth while working with lead. Make sure any cuts are bandaged.
Wear a dust mask when using whiting powder.
