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Hanging stained glass panels

Polar Bear Hanging Panel.
Dimensions no. pieces glass required.
12-1/4 in wide by 14-1 4 in high 26.
A    3 in x 3 in orange wispy.
B    6 in x 7 in white opalescent.
C    4 in x 12 in w hite wispy.
E    6 in x 12 in amber and white wispy.
E    7 in x 12 in light blue cathedral.
F    7 in x 10 in medium blue cathedral.
G    2 in x 12 in dark blue cathedral.
This quantity of glass is the exact amount needed for the pattern. You may have to purchase more glass. Please allow for matching textures and grain.
2 copies of pattern. Newspaper. Wood board. Wood trim. Masking tape. Black-backed copper foil. Safety flux 60/40 solder 1/4 in single channel. U-shaped zinc came 18 to 20 gauge tinned copper wire. Neutralizing solution. Black patina. Wax or finishing compound. Black sign paint. Monofilament line (fishing line).
Apron. Safety glasses. Utility knife or scissors. Permanent waterproof fine-tipped marker. Cork-backed straightedge. Glass cutter. Running pliers. Breaking pliers. Hammer and nails. Glass grinder 1/4 in drilling/grinding bit Soft cloths. Lathekin or doweling. Soldering iron and stand. Natural fiber sponge. Cotton swabs. Sidecutters or lead knippers. Rubber gloves. Fine steel wool (000) Toothbrush. Tracing brush. Cup hook screws.
Preparing the Pieces:
Follow the construction method for Small Hanging Panel.
NOTE: Grind out the tight inside curve (where the ear piece fits into the front leg piece) with the 1/4 in drilling/grinding bit. Also a wider zinc came is used in this project.
The following steps are in addition to the construction method described for Small Hanging Panel.
By making a hole in the light blue cathedral glass, the piece representing the sun can be placed in the sky without the use of unnecessary solder lines. Trace the outline of the sun onto the light blue glass piece. Wearing safety glasses and using the 1/4 in drilling/grinding bit on the grinder, drill a hole in the center of the traced sun outline on the glass. Once the initial hole is made with the drilling bit, slowly grind the opening large enough for the regular grinding bit to fit through.
Using the regular grinding bit, carefully grind away the glass to create a large enough opening for the sun piece.
Copper foil the edge of the hole created in the sky piece, taking care not to tear the foil when burnishing it to the glass. Trim any excess foil where the 2 ends meet.
Insert the copper foiled sun piece into the opening and bead solder  in place. Care must be taken not to crack the large sky piece by overheating while soldering.
Creating the detail for the Polar Bear’s Ears:
Copper foil the ear pieces. Trace the shaded portion of the pattern on the glass.
Apply just enough copper foil on the glass surface to cover the marked area and overlap the edge of the piece (this will help prevent the foil from lifting off the glass when the pieces are being soldered). Burnish the foil tightly to the glass. With utility knife, trim to match the pattern.
When the panel is being soldered, apply a bead of solder to the foil overlay, completing the detailing for the bear’s ears.
Creating the Polar Bear’s Claws:
The bear’s claws are pieces of tinned wire soldered to the seam of the foot. See pattern for placement.
Attaching the Hanging Loops:
Because there are no solder seams intersecting with the zinc border came along the top of the panel, the loops can be soldered to the top outside corners so that the loops are attached to both the top and side pieces of the border came.
Clean the panel.
Apply patina.
Apply finishing compound or wax.
Creating the Polar Bear’s Facial Features:
Using a tracing brush and black sign paint, paint the facial detailing on the bear’s glass head piece. Allow to dry.
Screw cup hooks into the window frame. Hang the panel, using heavy monofilament line (fishing line). Suction cups are not recommended because they dry out, allowing the panel to fall and break.
Because exposure to the sun’s UV rays can damage the monofilament, check it occasionally and replace as needed.

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