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How to make stained glass panels

Small Hanging Panel.
2 copies of pattern.
Wood board.
Wood trim.
Masking tape.
Silver-backed copper foil.
Safety flux.
60/40 solder.
1/8 in single channel.
U-shaped zinc came 18 to 20 gauge tinned copper wire.
Neutralizing solution.
Wax or finishing compound.
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 Soft cloths. Lathekin or doweling. Soldering iron and stand. Natural fiber sponge. Cotton swabs. Sidecutters or lead knippers. Small square. Toothbrush. Cup hook screws.
7-1/4 in wide by 9-1/4 in high 13
A 5-1/2 in x 7-1/2 in lilac wispy
B 3 in x 5 in grape cathedral
C 3 in x 4 in clear textured
D 2-1 in x 2 in clear rectangular bevels
E 2-1 in x 6 in clear rectangular bevels
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.
Preparing the Pieces:
Make 2 copies of the pattern on page. Use one copy as a guide for cutting and breaking the glass pieces. Use the second copy for fitting and soldering the panel together.
NOTE If you use opalescent glass make a third copy and cut out the required pieces to use as a template.
Using the marker, trace  each pattern piece on the glass to be cut.
Cut each piece of glass required, making sure to cut inside the marker line. Use the cork-backed straightedge to assist in scoring straight lines.
Make a jig to help fit the glass pieces together accurately.
Grind each piece of glass, as required, to fit the pattern. Remember to leave enough space between each piece so that the pattern line is visible between each piece (1/32 inch in width). After each piece is ground, rinse under clean water to remove any grinding residue and dry with a clean cloth.
Verify that the precut bevels fit the pattern and grind to fit where they do not.
Choose the width of copper foil appropriate for the thickness of the glass (7/32 inch is most common). Wrap each glass piece with the copper foil, crimp, and burnish down the edges with the lathekin or a piece of doweling.
Arrange foiled pieces on the pattern in the jig and tack solder  the pieces together.
Tin all exposed copper foil on the interior seams. Remember to solder no closei than 1/4 inch to the outside edge. Space mus be left along the edge to allow for ease of fitting the zinc came border.
Bead solder  the seams of the panel. Achieving a half-round raised seam will strengthen the panel and finish its appearance.
Turn the panel over and repeat steps 9 and 10 Since there is no right or wrong side to a stain ed glass panel and it is viewed from both sides strive for even solder seams on both sides.
Using a pair of sidecutters or lead knippers, cut a length of zinc came for each side of the panel. Use the pattern as a guide for the length required. Cut the end of each length at a 45° angle.
Fit the zinc came onto the edges of the panel. If the glass is thicker than the channel in the came, use a lafhekin to widen the channel. This makes it easier to fit the came around the edge of the glass. Use masking tape to hold the zinc came in place until it is soldered to the panel.
Solder the zinc came in place at each point it meets a solder seam on the panel and at each of the 4 corners. Repeat on opposite side of panel.
To make the hanging loops for the panel, wrap the tinned wire around a small cylindrical object (doweling or pencil) several times to form a coil. Slide the coil off, and using a pair of sidecutters or lead knippers, cut individual loops off the coil.
Place loops so that the panel hangs properly and safely. Attach the loops to a solder seam that meets with the border to prevent the border came from pulling away.
Clean the panel.
Use heavy monofilament line (fishing line) to hang the panel. Screw the cup hooks into the window frame and hang the panel Suction cups are not recommended because they dry out, allowing the panel to fall and break.

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