This old came stained glass door panel had reached the point where if it was not removed from the door it was in great jeopardy of collapsing and being ruined forever. As you can see in the picture below, the frame was coming apart. While not visible when you pushed slightly on the center, the whole panel moved in and out a lot and would completely fall apart if the door was slammed or someone pushed on the panel to open the door. Only 1 piece of glass was missing (the amber piece on the top right) while the rest was all in its original state. When restoring these old came panels we securely fasten a sheet of white freezer paper over the whole panel, then using carbon paper we do a rub to have a pattern for restoration.
The panel measured 22 inches wide by 26 1/16 inches high including it’s 3/8 inch zinc frame. The process involves carefully removing the panel and transporting it to our studio. In the restoration process we take multiple photographs and number each glass piece. The challenge in this restoration was the very wide came originally used and not replaceable. The reason for the wide came was for the bevels which were made from very thick glass.
This presented a problem for restoration as we needed to use H Round Zinc Came 1/4 inch face to ensure a strong interior strength coupled with 3/8 Zinc Border Came. We solved this problem by using a standard grit Aanraku Ripple Bit. This allowed us to grind down each side of these very thick bevels so they could be inserted into the new round zinc came. However it was imperative that we grind each side equally so we practised on a bevel that we had in stock. Then through trial and error we set up the ripple bit to ensure removal of the same amount of glass from each side of the bevel before inserting them into the panel.
The following photo shows a portion of the panel with all of its pieces numbered, we then carefully took the panel all apart and that is when we found out how very thick the glass was in these old bevels.
In the next photo we have now taken the rub pattern and set up a wooden frame, complete with the 3/8 zinc border came, ensuring that we have the measurements exactly so it will fit back into the original wooden door which our client was getting restored. Please note on the right side there are a couple of pieces of the very old came originally used.
The last photo is of the completely restored panel. Fortunately we had a piece of old glass that matched the one broken piece in the panel. We cleaned each piece of glass, carefully measuring and cutting the H zinc came. After soldering the joints we use Glass Pro Stained Glass Putty to cement the glass and then cleaned with whiting, after which we applied Clarity Polish. In this particular case we did not patina any of the zinc came as we felt it was not required in this restoration.
Designer Unknown – Restoration by Bob & Flory Wilkins
For one of our sons and family we made this transom window. It measured some 66 inches wide by 10 inches high. It was recently installed over their front door in Leduc Alberta.
We incorporated the East Coast Bud design from our Glass Eye 2000 stained glass computer program from the initial design by Jan Williams. This was a Victorian Panel design Circa 1837 -1901 originating on the East Coast of the USA.
For the border glass we used Youghiogheny 900DSR a Dark Blue Waterglass. This is a beautiful art glass however for the inexperienced stained glass artist it can be difficult to cut as well as foil but the end result is well worth the effort. The East Coast Buds were made from Bullseye 2311-30 a Cranberry Pink & White Double Rolled.
The clear glass was Spectrum’s SP – 100B Barnwood, which we were able to procure prior to their selling of their business to Oceanside Glasstile in Carlsbad California. Fortunately we were able to match the barnwood across each section of the 3 Buds and the way it ended up the panels blended extremely well together across the full width of the design.
The first photo is taken from inside the home and one can see how the Barnwood glass matched across the window.
The next photo was taken from the outside of the home.
The next photo shows the transom above the main entrance beveled door and it’s beveled side panels.
After printing off the design from our Glass Eye 2000 program we bordered the pattern using the Morton Layout Blocks system. We had to make sure that all of our measurements were exact and would fit the inside of the window frame. As well we used In-bedded strengthening braid to ensure panel strength and longevity.
The following photo shows the panel all ready for soldering. Once soldered we use Kwik Clean to remove solder flux. Then we cleaned the solder seams with #0000 Steel Wool applied Jax Pewter Black Patina, then cleaned the panel again with Kwik Clean. Finally we apply Clarity Stained Glass Polish and once dry use soft clothes and tooth brushes to clean and polish the panel and it’s solder seams.
Adaptation East Coast Bud design by Jan Williams
from Glass Eye 2000 computer program by Flory & Bob Wilkins
The Rafter Double U Ranch Cattle Brand commission measured 16 inches high x 40 inches wide. The brand was inserted into a china cabinet door frame. This was an interesting commission as we combined 2 inch sq bevels and Spectrum # 451-20W Ruby Red Waterglass for the border and brand.
For the centre portion we used Spectrum # 100B Clear Barnwood, however it was a tricky layout and cutting of the barnwood glass as we wanted to match it across the brand. The barnwood glass is raised and all of the pattern had to be laid out on the reverse side of the glass where much time was needed to ensure that the glass matched. When one is doing this kind of matching one only has one chance to figure out things and cut the glass accordingly or no more matching and or starting all over on a new sheet of glass.
We were most fortunate to have been able to obtain the Spectrum glass our clients wanted before the closing and sale of Spectrum Glass Company last year.
To help us with this design we once again enlisted the design help of Martha from Paned Expressions Studios in Edgewood Maryland.
The panel had to fit exactly into the reverse side of the cabinet door and the outside was surrounded with Cascade Zinc # ZB 932 which has a width of just over 1/4 inch.
The first picture shows the completed design before being inserted into the wooden cabinet frame.
The cabinet frame had a 30 – 40 year old came stained glass panel which our clients did not want. We had to remove it, then clean out the old glue/cement and we found new rubber replacement material to hold in the new brand. Before installing the rubber, we used a clear silicone cement, then carefully hammered in the rubber material into a thin slot in the wooden frame.
The following picture shows the brand installed into the cabinet door frame.
The last photo is the brand and frame all installed in their ranch home.
Their Cattle Brand is a Registered Alberta Brand
Brand Panel designed by Paned Expressions Studios
This beveled cluster transom window measures approximately 12 inches high x 36 inches wide.
We made the same design a couple of years ago for our clients farm home SW of Olds using the same bevel cluster with Spectrum’s Sky Blue Wispy in the centre with the border made from Spectrum’s Clear Artique.
This time our clients wanted to have the border made from Spectrum’s # 100B – Barnwood and for the centre Spectrum’s #6022-82CC Congo Pearl Opal. We fortunately had sufficient lead time from our clients that allowed us to obtain these Spectrum’s glass before their closing and selling of their business last summer/fall of 2016.
The next picture shows the window installed in a new duplex in Olds Alberta, initially a temporary piece of molding was employed until additional material could be obtained and it is now all properly completed.
Design by Flory & Bob Wilkins
Once again we were given the opportunity to make an Alberta Rose interior transom window for a new duplex in Olds Alberta. The window measured 36 inches wide x 12 inches high. For the border we used Spectrum’s 6022.82CC Congo Pearl Opal and in the centre we were fortunate to obtain a full sheet of Spectrum’s 100B Clear Barnwood which we matched across the window.
We previously made a similar Alberta Rose window using different glass which we featured on our website a few years ago for the same clients farm home SW of Olds, Alberta. (see link below)
The first photo shows the completed window prior to installation in our clients new duplex.
The next photo shows the transom window installed above the bedroom door way.
We use the Morton Layout Block system when building windows to ensure a precise fit. This photo shows the layout blocks holding in place the 3/8 zinc came border, with the border glass fitted along with the Alberta Roses foiled and burnished.
It is somewhat time consuming to fit and match the Barnwood glass, as all of the patterns are traced using white freezer paper that we obtain from Safeway, then glued on the smooth reversed side of the barnwood. There were five separate pattern pieces for each panel. We started on the left side and did each section ensuring that we cut and continued to match the barnwood glass across the whole window. The best advice we can offer anyone doing this is to take your time, measure and check numerous times before glueing your pattern to the glass and then scoring, breaking, grinding, fitting and foiling each piece. On each of the 3 panels we started at the bottom and worked our way to the top.
When making a window like this using clear glass, where the solder lines will have black patina applied it is imperative that black backed foil be used. For cleaning we use Kwik Clean after soldering, again after the patina is applied and then apply Clarity Stained Glass polish, using soft cloths and toothbrushes to clean and polish the panel.
Design by Bob and Flory Wilkins