Expert: lyn buerger - 10/30/2009

Question
How do I pick the size of the lead came. The windows I make are between 2 feet and 3 feet in size. There are too many choices. How does one choose? Thanks,Stephen

Answer
Hope you didn't get the last entry I made. I started and then bumped the wrong thing and my computer locked up, had to reboot.

Anyway back to your question.

I personally don't like doing lead, by its nature it is weaker than copper foil and harder to brace.  Having said that.  There are some things you need to think about.

If you are doing lead and the pieces are all somewhat large, lead would be faster and you could use the 1/4 to 3/8.   Using Dap and cement to glaze the pieces.  If there are small pieces use the 1/4 so you can fit them together easier and the pieces are not covered by the lead, especially any bevels.  I will sometimes use a combination. Use copper foil where there are small pieces and lead or zinc when there are larger or straight pieces.  You can use a ribbon steel (copper coated) inside the seams of the copper foil (just solder over it)  and you can put the ribbon steel inside the channel of the lead.  This add 100s of times more strength to either method.

If you glass is in a high stress area be sure to brace it well. A front door that people may be actually pushing on the glass, areas where children might play, sky lights, etc.

On patterns with lots of straight pieces I would probably switch to zinc.

Brass coated lead and solid brass can also be another option, however the brass is very hard to cut and will wear out your cutting wheel very fast.  

Hope that helps in the planning process.