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Techniques
All of our designs are hand drawn to scale for your project. Each commission is unique and made custom to order so you will be able to select exactly what you want in your window. During our design discussions, we will go over your needs to make sure all concerns are addressed. Windows are ordered for many reasons: decoration, privacy, to frame a view or to capture personal interests in glass. As you will see on my site, I work in many styles so I know we make you a window you can enjoy for the long run.
Once the design is approved, it is drawn to a full size cartoon. If the order includes custom bevels, they are ordered at this point and the rest of the materials are purchased. If the work includes fused or painted details, those parts are cut first so they can be fired while the rest of the glass is cut.
All of the glass is hand cut in the traditional manner using hand tools. The glass pieces are put together with lead came. The lead comes in 6' long strips and looks like an H in profile. The glass fits into this H, and built in sort of a tongue and groove assembly. Once the window had been put together, the joints are soldered with a lead/tin solder, then flipped over to solder the other side. Now the panel is waterproofed with glazing compound and cleaned. Brace bars are added for panels that are over 4 sq feet and in active windows to provide strength.
Most of our work is assembled with lead came. Copper foil is used when the pieces are small or when dimension is added. Lead is buffed to a dark pewter patina which helps blend the solder joints to the lead color. Copper foil can be colored in different finishes.
I am photographing a job in progress and will be posting step-by-step pictures of the process in this section soon. Please come back to see how it's done in a few weeks.
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