The Traditional Lead Came Method is a classic technique used in stained glass art, characterized by the use of lead strips (called came) to hold glass pieces together. Here’s a comprehensive overview of the process, materials, and considerations involved:
1. Materials Used
Lead Came: This is an H-shaped channel made of lead that holds the glass pieces. It is malleable and can be bent to fit various shapes. The highest quality lead used in stained glass typically contains 99% pure lead, which oxidizes over time, developing a white hue without compromising durability.
Glass: Various colored glass sheets are selected based on the design. The glass may be handmade, which can introduce unique variations and imperfections.
Solder: Used to join the lead came at the seams.
Flux: A chemical used to help solder adhere to the lead.
Cement/Putty: Applied to weatherproof and secure the glass within the came.
2. Design Creation
Sketching: The process begins with creating a full-sized drawing (cartoon) of the intended design. This serves as a template for cutting glass.
Approval: The design may undergo revisions based on discussions with clients or collaborators before final approval.
3. Glass Cutting
Cutting Process: Using a glass cutter, the artist scores the glass along the lines of the cartoon. The glass is then broken along these scores.
Grozing: Edges are refined with a grozing tool to ensure a precise fit within the lead came.
4. Preparing Lead Came
Cutting and Shaping: Lead came is cut to size based on the dimensions of the glass pieces. It can be shaped to fit curves or angles as needed.
Types of Came: There are different types of lead came, including H-shaped (for joining glass pieces) and U-shaped (for framing edges).
5. Assembling Glass and Lead
Fitting Together: The cut glass pieces are arranged according to the design, and lead came is positioned around each piece.
Pinning: Pins or clips may be used to temporarily hold the pieces in place during assembly.
6. Soldering
Flux Application: A flux is applied at joints where lead meets glass to ensure proper adhesion.
Soldering Process: Using a soldering iron, solder is melted and applied along seams where lead came meets glass, permanently joining them together.
7. Cementing
Weatherproofing: After soldering, a special cement (glazing putty) is applied around the lead came to embed the glass securely and make it weatherproof.
Curing Time: The cement requires time to cure properly for optimal strength.
8. Finishing Touches
Polishing: After curing, excess cement is cleaned off, and polishing may be done to enhance both glass and lead appearance.
Final Inspection: The completed panel is inspected for any imperfections or areas needing touch-up.
Advantages of Lead Came Method
Durability: Provides a robust framework that can withstand outdoor elements when properly sealed.
Forgiveness in Design: Accommodates minor discrepancies in glass cutting since the lead can adjust slightly.
Historical Significance: Maintains traditional craftsmanship techniques used for centuries, often seen in historic churches and buildings.
Limitations
Detail Limitations: May not be suitable for highly intricate designs compared to copper foil techniques that allow for more detailed work.
Weight Considerations: Lead adds significant weight to larger panels, necessitating careful planning for installation.
Re-leading
Lead deteriorates over time as a result of exposure to elements. Re-leading entails removing stained glass windows and replacing old lead with fresh material while retaining the original artwork. This method helps to stabilize sagging or bowed panels.To summarize, the Traditional Lead Came Method is still a core technique in stained glass art, valued for its durability, historical relevance, and ability to produce beautiful and long-lasting works of art.
The Copper Foil Method, also known as the Tiffany Method, is a technique for assembling stained glass that was popularized by Louis Comfort Tiffany in the late 19th and early 20th centuries. This method allows for greater detail and complexity in stained glass designs compared to traditional lead came techniques. Here’s an in-depth look at the process, advantages, and historical context of the Copper Foil Method:
Historical Context
Origin: Developed by Louis Comfort Tiffany, the copper foil technique was designed to create lighter, more intricate stained glass pieces, particularly for lampshades.
Innovation: Tiffany acquired the patent for this method from Stanford Bray, who initially developed it. The technique allowed artisans to create more delicate designs that were not feasible with lead came.
Process Overview
Design Creation
Sketching: The process begins with creating a detailed design or pattern on heavy cardboard. Each piece of glass is numbered and colored according to the design.
Cartoon: A full-scale cartoon may be created to serve as a template for cutting the glass.
Glass Cutting
Tracing: The pattern is traced onto selected sheets of colored glass.
Cutting: Using a glass cutter, artisans score and break the glass along the traced lines.
Grinding: The edges of each glass piece are ground to ensure a precise fit.
Preparing for Foiling
Cleaning: Glass pieces are thoroughly cleaned to ensure proper adhesion of the copper foil.
Foil Application: Each piece of glass is wrapped in a thin strip of copper foil, which has an adhesive backing. This foil allows for soldering without needing lead came.
Soldering
Arrangement: The foiled glass pieces are arranged according to the design.
Flux Application: A liquid flux is applied to help solder adhere to the copper foil.
Soldering Process: Using a soldering iron, artisans melt solder along the seams where glass pieces meet. This creates a raised bead of solder, securing the pieces together.
Finishing Touches
Cleaning: Excess flux and solder are cleaned from the surface.
Patination (optional): A chemical patina may be applied to darken the solder lines, enhancing visual contrast with the glass colors.
Final Inspection: The completed piece is inspected for any imperfections or areas needing touch-up.
Advantages of the Copper Foil Method
Detail and Complexity: This method allows for intricate designs and finer details that are difficult to achieve with lead came.
Lightweight Construction: Copper foil assemblies are generally lighter than lead came constructions, making them suitable for delicate lampshades and smaller panels.
Flexibility in Design: Artisans can create more complex curves and shapes without being constrained by the rigidity of lead came.
Seamless Appearance: The absence of thick lead lines allows for a more seamless look, enhancing the overall aesthetic.
Limitations
Labor-Intensive: The copper foil method can be more time-consuming than traditional methods due to its meticulous nature.
Environmental Sensitivity: While copper foil can hold up well indoors, exposure to outdoor elements may cause adhesive failure over time if not properly sealed.
Conclusion
The Copper Foil Method changed stained glass art by allowing for greater artistic freedom and detail. It is still a popular technique among current stained glass artists, allowing them to produce gorgeous pieces that capture light and color in unexpected ways. Whether utilized in lampshades or decorative panels, this method is still admired for its beauty and skill.
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