Step-1 Design:

Choose your design with thought and consider what you are capable of accomplishing talent wise. Research the project and carefully select your glass and construction type. Put into place the needed components such as supplies, IE: foil, outer metal edging or wood framing, bevels, jewels, etc. Once everything is ready to go and your just dying to get started started - take a deep breath and please take your time.

Step-2 Pattern:

Tools: Foil Scissors & Regular Scissors

Once drawn there should be two copies, one for the pattern and one for the cartoon. Both drawings should have piece numbers that match the each other. In addition you might consider the grain or direction of glass. The pattern is cut and separated into tubs for the next step.

Step-3 Spray Pattern:

Tools: Spray adhesive, cardboard

After the pattern is cut, each piece of paper should be sprayed with a suitable adhesive. This will ensure that the pattern sticks to the glass surface during the cutting & grinding steps

Step-4 Cutting Glass:

Tools: Glass Cutter + Oil & Glass Pliers

(Leave the paper on…) Scoring the glass is a task that improves with repetition. Try a few practice cuts before jumping into that shinny new piece of opal glass just staring at you. Look around for a glasscutter that best suites your needs and one that is comfortable to hold. Start at the edge of the glass and make a nick, then with a nice even pressure on the wheel, run the cutter over the surface of the glass. Always cut from the smoothest side of the glass. The pattern can act as a guide for the wheel to score it’s cut. The sound should be similar to a clean quiet zipper. Then with your glass Pliers break the glass. Remember there’s no better way to learn how to cut glass then to practice on scraps.

Step-5 Grinding Glass

Tools: Glass Grinder or Abrasive Stone

(Leave the paper on…) When all the glass has been scored and broken out, try separating the different colors into tubs, this way you can find the pieces easier when you start to clean and lay them out. Grinding serves a two-fold purpose. It shapes the uneven or jagged edges of the glass that has been cut, and roughens up the edges of the glass so the foil tape will adhere to the textured surface. If you are working on a small project and feel your glass cutting skill is top notch, then you may only require the use of a abrasive stone to smooth out the rough edges if any. If your cutting skills are less then perfect or the glass is not cooperating then an electric glass grinder is the tool.

Step-6 Cleaning & Layout

Tools: Rags, paper towels, Windex

(Leave the paper on…) After the grinding step is completed, it begins to get a little more interesting and colorful. Now with all the glass ground and separated into tubs, take them to the table or work area where the cartoon is laid out. Start pulling one piece at a time and removing the paper, cleaning it carefully, especially on the edges where the foil tape will adhere. Remember to make a mental note of the number or identifier so you can place it on the corresponding number on the cartoon.

Step-7 Applying the foil

Tools: Foil Machine or Hand Foiler

The tape is easily applied to the edge of the glass using a tool designed for this specific purpose. The foiling machine makes quick work of a tedious task. The most common size foil I use is 7/32" and copper foil with a copper back is also the most widely used as well.

Step-8 Burnishing

Tools: Handy Roller or Blunt End, Lathkin

After the tape is applied to the glass, it must be smoothed out evenly over the outer edges of the glass surface until there is an even and uniform width from the outer edge. The photo shows foil tape as it is smoothed out. A simple object like the end of an exacto tool is shown here.

Step-9 Soldering

Tools: Soldering Iron, Flux, Solder, Ventilation, Gloves

Soldering is much like cutting glass in that practice makes you better at it. Foiled glass is soldered in a continuous line or bead along both side of the panel. On foiled glass work I like to use 50/50 solder on the front side for greater strength, and 60/40 on the opposite side. The soldering irons I use are also geared for specific applications. Try a temperature controlled iron for this type of work. A hot iron is ideal for foiled work, if you are experienced in soldering techniques. For those of you just staring out don't go to hot at first, but work your way up. And practice-practice-practice.

Step-10 Finishing

Tools: Rags, paint brush

To finish off that nice piece of art you just created, you must first give thought to the finish or "Patina" you want to use. The most common choices available are Antique Black - Bright Copper - Antique Brass. The patina is nothing more than a chemical that changes the surface coloring of the lead or zinc metal, that you have constructed the panel from. You simply apply the product following the manufactures instructions and recommendations.

Step-11 Framing

Tools: Square, Miter Saw, Rule, Pencil, Drill, Screwdriver, Clamps