Stained Glass

Stained Glass

Instructor	Kim Nguyen
Email	stainedglass@rocmakers.org
Revised	March 14, 2026

Welcome to the Glass Area

In this class, you will learn the Copper Foil (Tiffany) method. You will transform raw sheets of glass into a finished suncatcher by learning to score, break, grind, foil, and solder.

1. Design & Layout

Pattern Check: Make sure the curves/angles in the pattern are achievable in glass.
Organization: Number each cutout; write down notes for colors, textures, and/or grain direction.
Duplication: Make multiple copies as needed for stencils and templates.

2. Cutting Glass

Sequence: Trace and cut each piece before starting the next one.
Efficiency: Preserve as much of the remaining glass sheet as possible with each cut.
The Score: One score, one cut. Cut on the smoother side of glass (flip your cutout before tracing if you want the textured side on the front of your project).
Breaking: Use running pliers for straight breaks; tap the back side of glass for curves.

Safety: Cutting

Eye protection is a must for this (and every) step.
Never lean on your work surface (it may contain invisible slivers of glass).
Sweep up glass slivers after every few cuts — sweep slowly to avoid airborne glass dust.
Optional: Wear an apron or gloves to catch tiny shards.

3. Grinding Glass

Setup: Partially fill the grinder reservoir with water (~1/4 inch), soaking the sponge to create water flow.
Maintenance: Keep the sponge and wheel wet at all times! Add water periodically.
Marking: Use a Sharpie to mark areas of glass that require extra grinding.

Safety: Grinding

Water is essential to avoid hazardous airborne glass dust.
Glass can “kick back” if pushed onto the wheel at the wrong angle.
Cleanup is critical: Wet glass sludge is harmless, but dry glass powder is hazardous to breathe. Surfaces must be wet-mopped and reservoirs emptied when finished.

4. Applying Copper Foil

Prep: Thoroughly clean and dry all glass pieces before this step. Gently wipe/pat edges with alcohol prior to foiling.
Placement: Do not start tape on an edge that will be on the outside of the final project.
Technique: Attach tape and “roll” the glass piece towards you, keeping it centered. Guide the fold so it attaches properly.
Burnishing: Important: Burnish tape well with a Sharpie, pencil, or burnishing tool.
Note: Foil is easy to remove at first, but requires a scraper once pressed on.

5. Soldering

Layout: Securely lay out your project on the board with thumb tacks or straight edges.
Preparation: Remember to always apply flux first!
Technique: “Tack” solder all joints, then remove thumb tacks. Try to get a smooth raised bead of solder.
Heat Management: Avoid overworking an area. Let the piece cool to avoid “melt-through” on the other side.

Safety: Soldering (700°F+)

No Gloves: Never wear gloves while soldering; they can melt into a much worse burn. Wear an apron instead.
Fumes: Use a fan or ventilation — burning flux creates fumes.
Lead Warning: Solder contains lead. Wash hands immediately after and avoid touching your face/food.
Fire Safety: Always unplug the iron when done and keep it on its stand.

6. Applying Patina & Polish

Cleaning: Wait for the project to cool, then gently clean all flux off in the sink with soap and a paintbrush.
Patina: Apply patina, let sit a few minutes, and then gently rinse.
Finishing: Gently apply wax or polish onto the solder and clean the glass.

Clean Up

Leave the space better than you found it. In the Stained Glass area, mess is a safety hazard.

Stop 10 minutes before the end of your session to clean.
Clean all water splashes, powdery residue, glass shards, solder, flux, and patina.

Closing Checklist

Soldering iron unplugged
Grinders emptied; all surfaces/binders wet-wiped
Tools and projects put away
Work area swept and floor wet-mopped
Lights turned off

Supplies & Materials

The Makerspace provides the heavy equipment (grinders, irons, etc.). The class uses shop tools; independent projects require members to bring certain materials.

What do I need to bring?

The shop provides: grinders, soldering irons, glass cutters, pliers, flux, patina, and wax.

You provide for independent projects: glass sheets, copper foil (black-backed 7/32 inch recommended), 60/40 solder, jump rings, and personal safety gear (safety glasses, optional mask).

Member glass is only from the labeled clear plastic bins. Full or partial sheets outside those bins are reserved for classes.

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