How to Assemble Leaded Glass Windows
Make a stained, etched or beveled glass window by choosing a design, making a pattern and cutting it carefully. Arrange the glass pieces you choose so that they are the right size, shape and color you want. The assembly process involves nestling all glass pieces in lead came, which has an H-shape, making two channels to hold pieces of glass next to each other, and adding an outer frame of U-shaped came.
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Things You'll Need
- Paper pattern of window, at 1:1 scale
- Flat wood surface
- 2 strips wood lathe
- Nails
- Hammer
- Border pieces of lead, zinc or brass came.
- Lead came
- Lead vise
- Slip-joint pliers
- Lead knife or loppers
- Pieces of glass cut to pattern
- Horseshoe nails
- Tack hammer
- Wirebrush
- Flux
- Flux brush
- Soldering iron
- Solder wire
- Glazing compound
- Mineral spirits
- Newspapers
- Spoon
- 2 scrub brushes
- Plastic gloves
- Plaster powder or plaster of paris powder
- Angled popsicle stick or skewer
Instructions
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Begin Assembly
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1
Place paper pattern on flat wood surface. Nail lathe strips at right angles along two adjoining sides at the outer edge of the pattern/window. Place one end of lead came strip in lead vise, channel up. Clamp pliers onto other end of lead came and pull until lead is straight and taut.
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2
Cut two pieces of lead came to match the lengths of two adjacent sides of the window. Place them flush against the lathe-strip guides, came piece for short edge of window butting against longer side's full-length came strip. With flat side of horseshoe nails against outside of lead strips at intervals, hammer nails into wood surface just enough to hold strips in place.
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3
Slide the appropriate glass piece into the lead came at the corner where strips meet. Check that "free" edges of glass pieces align with pattern lines. Cut pieces of lead came one-quarter to one-eighth inch shorter than the length of each side of glass shape where it meets adjacent edges. Slide lead onto glass. Hold in place with horseshoe nails.
Complete Assembly
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4
Continue fitting lead came around all glass pieces. Add last two border strips. Keep came tight with horseshoe nails. Measure window dimensions. Adjust border came if necessary.
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5
Scrub joint where lead strips meet, using wire brush. Brush flux on joint area. Heat soldering iron. Hold solder wire against joint and press iron tip into wire. Lift iron when one-quarter inch of solder has melted to join the two lead strips. Solder all joints on up-facing side. Turn panel over and repeat soldering on second side.
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6
Mix glaze compound with mineral spirits to thickness of brownie batter. Put the panel on top of newspapers. Spoon glazing compound onto glass and work under edges of lead came and border, using a scrub brush in a circular motion. Brush away excess compound.
Cleaning Up
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7
Wearing gloves, sprinkle plaster powder onto panel. Spread over entire panel, especially along all lead and border frames.
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8
Apply glaze followed by plaster powder to the other side. Let set 10 to 15 minutes. Remove flux, glazing compound and plaster powder by brushing with a dry scrub brush parallel to each leading strip. Clean remaining residue from lead edges with skewer or angled stick.
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9
Lay panel flat. Do not disturb for 24 hours. Wash with soapy water and let dry.
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1
Tips & Warnings
Use lead, brass or zinc came for window borders.
Use paste flux on lead came. Liquid flux works better on copper foil.
Begin soldering in upper corner opposite the hand holding the soldering iron. Work down and diagonally.
Using a high-grade car wax or finishing compound after assembly is complete keeps lead from oxidizing.
Remove flux as soon as possible after soldering to avoid oxidation of came or glass clouding.
Cover pieces of heavily textured glass with clear, adhesive-backed plastic when glazing to avoid getting compound into glass indentations.
References
- Photo Credit vitrail image by aurore adeline from Fotolia.com
