Stained Glass Horses - COPPER FOIL (TIFFANY)TECHNIQUE
COPPER FOIL METHOD: Another popular method used for STAINED GLASS PANELS is the COPPER FOIL METHOD. This is used solely on interior installation as it it not weatherproof. (Copper Foil Method is the method used for Tiffany Lamps).
- A pattern is designed (Illustration shown below)
- Glass is selected for color, purpose and texture
- The glass is cut by hand.
- Then if necessary, the edges are marked and ground to fit inside the pattern lines.
- Glass edges of each piece are wrapped in a sticky-backed copper foil
- Pieces are assembled together on the pattern (cartoon) like a puzzle
- Next, I will "tack" solder the piece on both sides, just to hold the pieces in place. The window is very unstable at this point! Next, I will flux and solder the entire length of the copper foil. (Instead of soldering just the joints as in leaded glass, the copper foil is completely covered with solder on both sides.)
- Next, the zinc frame is added. For stability, I use zinc even when the piece will be installed in a wooden frame. If it is a round or oval piece, I bend the zinc with a bender, add it to the panel and solder the zinc together. I also solder along a few of the already soldered lines - dragging a bead of solder to the zinc to help hold the piece.
- Hooks are added if needed.
- The panel is cleaned thoroughly with warm water and mild soap or flux remover.
- Patina is added to give the piece an antique look.
- The piece is cleaned again.
- Polished with a light furniture spray
- Packing in insulation
- The crating and final STRESS TEST!
| Step 1: Pattern or "Cartoon" | Step 2: Select Glass |
 |
 |
| Step 3: Stained Glass Cutter | Step 4: Inland Grinder |
 |
 |
| Steps 5 & 6: Edges wrapped and assembled | Steps 7 & 8: Tack, solder, frame |
 |
 |
| Step 9: Hooks Added | Steps 10-12 Ready to Patina |
 |
|
| Step 13: Cleaned and polished | Step 14: Packing in Insulation |
 |
 |
| Step 15: Crating & Stress Test! | |
 |