The Copper Foil Process

We begin each window by creating a design, then decide which colors and glass to use. The design is drawn to full size and duplicated. The duplicate is cut out, which becomes pattern pieces for the glass. Once the glass pieces are cut, copper foil adhesive tape is wrapped and smoothed onto the edges that will be soldered. The window is then soldered on both sides and framed with zinc edging.

Click the arrows at either side of the panel of images below to see each step of the process.

The Lead Process

The assembly process of a leaded window is quite different than copper foil. The cut glass pieces are separated by strips of pliable “H” channeled lead. The glass edges must fit into each side of the “H”. As the window is assembled, it is held together with horseshoe nails on a wooden table. When all of the glass is cut and leaded into place, a zinc edge is placed around the edge of the window, held in place with nails. Then, on both sides of the window, the intersections where the lead strips meet are soldered, as well as connections to the zinc. After cleaning, the window is then puttied. Putty is pushed into the lead channel that is between each glass piece on both sides of the window. The excess is wiped away. After a few days to let the putty dry, the window is thoroughly cleaned.