Our Easy to Follow Copper Foil Method of Stained Glass Creation

Below is a synopsis of this stained glass process. We have used this process to make many types of stained glass pieces and one that we are well versed on.

Note: Don’t worry if following text is tough for you. We’ll be adding copper foil videos and other tutorials for you as we go.

Let's dive right in and cover some basics of the copper foil method...

Picking a Pattern:

If this is your first time or in your beginning phases of stained glass making, picking a pattern can be a ton of fun! It is best you choose something you will like to make, but also has fairly easy cuts.

It is best to look for a pattern with straight cuts so you can use this to practice cutting. Something with diamonds, triangles, or squares would be a great choice.

There are many types of stained glass patterns resources you can brainstorm from. People, flowers, abstract designs, animals, and objects are just a few examples.

Pick Colors and Textures of Glass:

Once you have chosen your design, the next item of business is to choose the type of glass and colors you desire. You can follow the pattern colors if chosen from a book, or you can pick your own textures and colors.

If you do an abstract design, you can choose a variety of colors or several colors that are dispersed unevenly throughout the pattern. It would be good to pick your favorite colors or colors that look good together. Also, there are varieties of texture, such as smooth, bubbly, wavy, two-toned, or raised.

For example, if you want to make an all clear copper foil design, you can find glass with all the different textures listed above.

Marking the Pattern and the Glass:

Lay the pattern flat on your work table. Mark each area with the color and texture you wish to use. Once all the areas have been marked, you will be able to imagine the final product. Remember, you can always change your colors around with an abstract design.

Get revved up because this is just the beginning of the exciting creativity of a beautiful stained glass design.

Cutting the Glass:

Now that you have picked your pattern and the colors of stained glass, it is now time to begin the cutting process.

You will need to score from one edge of the glass to another edge, so you will be able to break away a section at a time of the unwanted glass.

You can cut all the same color pieces at the same time or you can cut sections of different colors. It is completely up to you.

OK. Now are the crucial stages, so listen carefully!!! Take your first piece of glass - it doesn’t matter where you begin in the pattern – so the creativity starts.

Put the glass right side up over top of the pattern piece (right side is the textured side). Outline the piece you want to cut with a permanent, fine gold marker. Tip: We find gold the best and easiest way to follow and see the line during the scoring process.

Flip the glass over to the back side (smooth surface). With the glass cutter, follow one line (each side of the piece) at a time with a firm pressure scoring the glass on the line. This will not cut the glass all the way through, but will allow you to break it easily.

Important Tip: Only score the lines once. Do not go over the score.

Breaking the Glass:

There are several methods to break the glass.

• Tap along the scored edge with the metal handle of the glass cutter until the glass breaks loose. This method is best for rounded and curved edges.
  
  
• If you are cutting a straight line, score the glass in the same manner, but break the glass by using the edge of a table. Put the score line on the edge of the work table, take a firm grip of the glass, and push down against the edge of the table.We put the usable piece on the table and the balance of the glass over the edge. This should allow the glass to break easily along the score.
  
  
• Also, we like to number each piece on the pattern as well as each piece of cut glass so assembly will be easier.

Continue scoring and breaking each edge of the pattern until you have it complete. Put the piece on the pattern so you can see the design come to life. Continue cutting each piece until all are cut and placed on the design.

Smooth the Edges:

Now that all the pieces are cut and set on the pattern, the next step is to smooth the edges of each piece of glass.

By the way, doesn’t your design look wonderful thus far? If not, don’t worry, we just have more copper foil work to do together. Any which way, if you have gotten this far, then pat yourself on the back.

It is good to smooth the edges so that applying the foil will be an easier process. Sharp edges can be removed in two ways:

• Rub the edges with a carborumdum stone. Remember to keep it wet so the dust level stays at a minimum. Also, ventilation is important at this step.
  
  
• Utilize a grinding machine. This is an expensive piece of equipment, but a worthwhile investment if you are to continue this art. Using a grinder will speed up the process of smoothing. If you use a grinder (discover the benefits of the wizard grinder here), let the wheel do the work. Take your time smoothing and getting rid of unwanted areas of glass.

Clean off the dust and put the pieces back into their proper place on the pattern.

Copper Foil:

After all the edges have been smoothed, it is time to apply the copper foil to the glass edges. Copper foil is used to cover the raw edges of the glass making it easier to solder together.

Copper foil can be purchased in precut rolls and in different widths. If you use a wider copper foil, this will result in a wider seem on the front and back. A smaller width foil is best (in our opinion) to use for delicate or smaller pieces (this allows the glass art to stand out better).

To apply the adhesive side of the copper foil, you put it up to the glass edge and press it firmly all around the edges. Be sure to overlap where you began.The tape needs to be evenly applied along the edge so the overlap is not noticed.

Next, fold the excess of the foil onto the front and back of the glass. Press down firmly. You can use your fingers or a tool called a fid. A fid is a plastic tool to smooth the copper foil all around. The fid helps protect your fingers from getting splinters of glass in your hand.

This will result in a wider SEAM!!

Solder:

Now that all of your pattern pieces are cut, smoothed out, and foiled, it is time to solder.

First, step back and notice how much you have achieved at this moment. Remember to enjoy the process. It’s the journey, not the end result that provides the most pleasure.

Tools you are going to need to solder. A soldering iron is a must. Be sure to preheat before you begin. Kind of like a hair curler for you ladies. Solder which you should cut to lengths needed or unroll it for easy application. Finally, flux which comes in the gel form, liquid, or paste. You are going to apply this in small areas with a brush on the foil. This helps the solder to flow nicely.

Where you have applied the flux, melt the solder enough to hold the pieces together and in place. It is good to solder the joints together first then go over the lines of the glass. Move the soldering iron and the solder slowly to form a bead and spread it along the foil.

Keep your solder tip clean so the solder will flow easier. Use a damp sponge to perform this task. Once you have soldered the entire front of the design, turn the design over and complete the process on the back. It is best to practice soldering two pieces of glass together before doing your pattern. Click here for more tips on stained glass soldering.

Don’t worry we’re almost there – Cleaning the Glass Design:

After soldering is complete on the front and back, wash the entire patterned glass with warm, soapy water to remove any dust and debris that may have run onto the glass. You can also use a straight edge razor to pop off any solder that has dried on the glass.

Patina:

If you want, you can color the silver solder by adding patina. Color choices will be copper or black which you may have seen on other glass products.

Apply the patina with a soft cloth or small brush for the best result. We recommend wearing rubber gloves as you spread it over the solder to protect you hands and fingers from the chemicals.

Washing Again and Waxing:

Wash again with warm, soapy water. Then apply a thin coat of car wax over the entire pattern. You could then buff with a soft, dry cloth for a shiny luster!

Finishing:

To finish the pattern you just busted your butt on, you can add a chain hanger or frame with wood or metal channeling. This is another part of the process where you can be as creative as you wish.

Finally, hold you piece up in front of a window and admire your fun, yet hard effort. Isn’t it a beautiful accomplishment and great feeling? Now it’s time to move on to the next design. It just gets better from here…

We hope this has helped you envision and learn the copper foil process. We'll be getting into the lead came process of stained glass in another section. Feel free to ask us questions anytime and share your stained glass making with us.