In beginning a new panel, we meet with the client to determine the subject matter and style. When a design is approved and exact field measurements are taken, production of the panel can begin. Often panels can be installed into existing window frames with few modifications.
Full-scale patterns are drawn and, if required, the design is refined from a projected enlargement of the original.
Glass pieces are cut from selected colors. Paper patterns for each piece of glass in the design contain information on color and location.
Any painted elements in the design are applied and these glass pieces are kiln-fired at 1,250¡ F. to make the metal-oxide pigments permanent.
The panel is assembled with individually cut lengths of extruded lead called came. The glass pieces are held in place by the overlapping profile of the lead came.
All intersections of lead are soldered to create joints that bind the lead together into a matrix.
The panel is rubbed with a tinted, oil-based putty compound, which waterproofs the panel and adds a patina to the lead.
After excess cement is removed and allowed to cure, the cleaned and completed panel is ready to be installed.