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Stained Glass - assembly of very large window
Expert: lyn buerger - 10/20/2009
Question
I have been asked to do a 52" x 40" window. I have never done a window quite that large before, the biggest size I've worked on is 44" x 26". I've always only worked with copper foil in the past. I was wondering if a panel that size needs to be leaded or is it still possible to use copper foil for assembling. And How do assure its strength. Should I be sure to use a rebar strip across the back of the panel?
Thanks for your suggestions!
Lori
Answer
Big ones are always scarry. I personally like copper foil better and by its nature is stronger than a leaded piece. Lead is so soft and subject to stretching and bending. My biggest piece was 48x60 and it was copper foil.
Suggestions:
1) can the piece be subdivided into sections and installed as 2 or 3 separate pieces? I've done that with great success, but my patterns were easy to make work that way.
2) You can add a copper covered steel "ribbon" inside of the copper foil and just solder over the ribbon. Use it is any places on the piece that will add to the strength. A series of cuts that go all the way across the pattern should be avoided or add the steel internal bracing. The ribbon easily bends and shapes to the curves but it will not bend sideways.
3) You can also add outside rebar to the back side of the piece.
4) be careful moving it. I build and transport on a piece of plywood and a plywood sandwich with the glass between Don't let the piece torque (bend) while moving.
You can see some of my items on my website www.lyn-arts.com But I've always been bad about not taking picture, so there are no pictures of my biggest one. The pink roses was about 40x50 and was copper foil with internal bracing and no outside bracing. In a bathroom above the tub.
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