Lead came and copper foil glasswork

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A typical copper foil Tiffany lamp, with a jonquil daffodil design

Lead came and Copper foil glasswork are the arts and crafts of cutting colored glass and joining the pieces into picturesque designs.

The traditional method uses lead came. This is the method used for centuries in Europe, mainly in Religious buildings such as cathedrals, churches and monasteries, and including wealthy or aristocratic homes.

An alternative method, replacing the lead came with copper foil, was invented in the 19th century, enabling creation of three-dimensional works, in addition to two-dimensional ones to which the lead came method is limited. The copper foil artwork is commonly called Tiffany stained glass, even though there is a debate about whether John La Farge or Louis Comfort Tiffany invented this alternative to lead came glasswork.

Contents

1 Overview

2 The process

2.1 Design

2.2 Transferring the design to glass

2.3 Cutting the glass

2.4 Grinding the cut glass

2.5 Glass saws

3 Lead came technique

3.1 Preparation of lead for assembly

3.2 Assembling the lead and glass

3.3 Soldering the lead joints

3.4 Cementing the lead and glass panel

3.5 Adding reinforcement bars

4 Copper foil technique

5 Tools and materials

5.1 General

5.2 For lead came work

5.3 For copper foil work

6 See also


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Overview

In both lead came and copper foil glasswork, cut pieces of stained glass are joined together in a framework of lead.

In the lead came method the pieces of glass are embedded into the channels of the came, and the joints between the came strips soldered together.

In the copper foil method, the edges of the glass pieces are wrapped with adhesive copper tape, and soldered together along the adjacent copper strips.

The process



The steps in creation of Lead Came and Copper Foil Glasswork

Design

The first step for both techniques is to create a design on paper. This draft must consider constraints such as reduction of buckling risk, overall structural integrity, limiting the convergence of lead lines, and cuttability of each piece of glass within.

The next step is to make a template copy of the design for cutting the glass. The width of the lead came or the copper foil that separates the pieces of glass may be compensated for with double blade pattern shears that remove a thin strip of material on the template copy.

For large designs, a scale model may be made, which is digitally photographed and further modified with AutoCAD. After measurements and other notations are applied, the full pattern is printed on a large-format printer.

Transferring the design to glass

Four methods may be employed.

The cut paper may be glued to the glass before cutting it

The cut paper to may be pressed against the glass and its outline traced on the glass with a marker.

The pattern may be affixed to a light box or light source. Sheet glass is placed over the pattern, and traced with a marker.

The edge of the pattern piece may be followed with the cutter.

Cutting the glass

The glass is scored using a steel or carbide wheel glass cutter lubricated with cutting oil. Glass is broken at the score using breaker-grozier pliers, running pliers or built in groziers on a traditional glass cutter. This works because glass breaks along its weakest point when it bends. The ball end on many glass cutters is used to break complicated cuts in a piece of glass. Tapping the ball end along the score on the opposite side of the glass sends a vibration through the glass that helps it break along the score. Also, the notches in most basic glass cutters can be used to grab small bits of glass for breaking.

Grinding the cut glass

At this stage, the cut glass pieces have sharp edges and inaccuracies in their shape. The glazier can use an electric glass grinder with a diamond-coated grinding wheel to smooth the glass pieces, or a carborundum stone.

Glass saws

An alternative to the cutting and grinding steps is the use of a ring saw or band saw. Such saws permit the cutting of shapes impossible with a wheel cutter.

This is where the processes for each of the two methods split. The next section describes the steps for the lead came method. The equivalent copper foil steps are described in the copper foiling section below.

Lead came technique



A 16th century lead came glass window, church Notre Dame, Les Andelys, Normandy, France

The lead came has channels into which the glass pieces are inserted. There are two types of lead came: for the circumference of the design, came with a U-shaped cross section may be used, as it takes glass only on one of its sides. For the middle of the design, came with an H-shaped cross-section is...(and so on)
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