How to Solder Copper Foil

Solder copper foil correctly.

Copper foil is what gives stained glass a look of being almost three-dimensional. There are many advantages to using copper instead of another metal. It is stronger than lead, doesn’t need to be puttied, is waterproof and can be smooth against the glass in areas where the bulkiness of other solders would be distracting. Soldering copper foil may take some practice, but it can add elegance to a piece of jewelry or a lamp.

Things You'll Need

• Tape measure
• Pen
• Paper
• Copper foil with adhesive on one side and protective paper on the other
• Small piece of wood
• Flux and brush
• Soldering iron
• Solder
• Patina and brush

Instructions

1. Measure the pieces being soldered and write down the number and sizes of copper you will need. Lay the spool of copper on a table. Cut the pieces to the sizes you have written down.

2. Remove the backing of the copper foil. Take one piece at a time and crimp along the edge of the pieces needing to be soldered. Try not to overlap. Fold down the edges neatly and as close to flat as possible. Using a small piece of wood, burnish the edges down as smooth as you can.

3. Position all the wrapped pieces in the pattern that you are making. Use pieces of wood to keep the edges square. Tack the pieces together with a drop of solder. Use just enough to hold it together. Apply flux to the seams of the pieces you are going to solder immediately otherwise it will tarnish.

4. Move the soldering iron with the tip held horizontally, and the solder along the seams. This is called beading. You need enough solder for uniformity up and down the seams, but not so much that it cannot be controlled. You will learn the correct amount as you do it. Bead both sides of the piece.

5. Decide if you are going to frame your piece before you start. If you are not framing with wood, bead the outside of the piece all around. Apply a light coating of solder to perimeter on both sides.

6. Take the piece and hold it with the edges to be soldered horizontal to the table. Melt enough solder so that it rolls down the sides of the foil, uniformly rounding the edges. This will make your piece stronger and give it a more finished elegant look. When the sections are curved, do ½ an inch at a time. Allow to dry and then proceed to another ½ inch. Solder loops for hanging if you are not framing the project.

7. Wash the project with warm water and a very mild detergent.

Tips & Warnings

• If the solder and copper seem varnished, make a mixture of water, vinegar and salt and apply. Read the directions on the container of patina. Apply the patina over the project. Choose patina carefully, as it will change the color of the solder. Allow project to set for a day.

• When using patina, wear rubber gloves to protect your hands from the chemicals. Follow the directions on the label and wash and dry thoroughly after using the patina.

References

• Inland Craft: HT Sold
• Delphi Glass: Basic Soldering Techniques