Objects are designed, sketched out, a pattern is made if necessary and then the labor intensive process begins.
Step 1 > Cutting The Glass > Each piece of glass is hand-cut, then a tool called a grinder is used to shape the glass to fit perfectly within the design and sharp edges are filed down. Each piece of glass has to fit together like a puzzle piece without gaps. If an object involves mirror, a mirror sealant is used to coat and seal each mirrored piece to protect it from turning black.
Step 2 > Copper Foiling > This is also known as the Tiffany method. Glass edges are wrapped with copper foil tape and then burnished. This allows the pieces to be soldered.
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Step 2 > Leading > Pieces of lead came are cut to size and used to border each piece of glass.
Step 3 > Soldering > Each piece is soldered together. Majority of stained glass out in the world is soldered with solder that contains lead. This is the traditional way and most common way of doing stained glass. The use of lead in stained glass causes very minimal risk and is not harmful to handle. It is only harmful if ingested or inhaled but it's always a good idea to wash your hands after handling as a precaution. Most of my pieces are made with 60/40 solder (60% tin, 40% lead) and pieces that are often handled like catch-alls are made with lead-free solder (99.3% tin, .7% copper).
Step 4 > Finishing > Glass is finished with either black patina, copper patina or it is left silver then polished. When treated with black patina, the results are dark bronze to a dark gunmetal appearance not a true black. Copper patina is a shiny copper color but does tend to dull over time. The finished object is then waxed and polished.