Leaded Glass Windows

The original and most popular method used when creating a stained glass windows is lead came. There are other metal cames available besides lead, these include zinc, brass and copper. Lead is a durable, long lasting, low-corrusive metal, this makes it a good choice because it will last a long time. The came is produced in six foot long strips which are cut down to size as needed. Another method is making stained glass windows with copper foil.

Creating a stained glass window is a several step process. Here is a break down of the individual steps

Designing the window. The first step is to draw a design of the window you wish to create. I like to start with a 1/8 scale. Keeping the design in scale will help you later when you need to draw the pattern to size. When satisfied with the design it's time to make a pattern.

Making a pattern. This step entails drawing your design to the actual size of the window. Since the original design is in scale it is relatively easy to increase the size. The design is made into a pattern either by drawing it free hand, making a larger copy or by using software. After the pattern is made to size individual areas of the design are numbered and labeled by color. Now a copy of the pattern is made. One of the patterns is used to lay out the window, the other is used to make patterns to cut the glass. The pattern used to cut the glass is cut into pieces on the design lines with special pattern shears that allow for the heart of the lead.

Cutting the glass. The next step is to cut the glass. There are a few ways to do this. One way is to place the paper pattern on the glass and hold it in place while cutting around the perimeter with a glass cutter. Another way is to place the paper pattern on the glass and trace the perimeter with a grease pen, then remove the pattern and cut on the pen line. Some artists prefer to spray mounting glue on the pattern and stick it to the glass and cut around the outside edge. It is important to place the pattern on the piece of glass after it is cut to know where it goes on the layout pattern.

Laying out the glass pieces. At this stage all the pieces of cut glass get laid out on the pattern. Use the numbers on the cut out pattern pieces to place the glass in the corresponding spot on the layout pattern.

Leading the window. The window is now assembled similar to how a jig saw puzzle is made. The lead came is cut into small strips that are place between the pieces of glass. Lead is a very soft metal, so it easily bend to the contour of the cut pieces of glass. Once all the pieced have been leaded together, a small amount of solder is applied to all the jints where the lead meets to secure the panel.

Sealing the window. The final step is to seal up the window. We do this by brushing a putty type mixture between the lead and the glass. Then a white powder is brushed on the window to clean up the residue left by the putty mixture. Once dried this will make the window weather proof