Michael Johnston - Making Stained Glass Boxes

introduction

A colorful stained glass box can be a wonderful complement to any home decor while it safeguards treasures, keepsakes, jewelry, and more. In this book, we have detailed all the steps for making an elaborate glass jewelry box.

Three-dimensional items generally require some previous experience, particularly in the basic skills of cutting and soldering. Because of this prerequisite, we have included teaching primers in both areas in order to prepare you for the successful completion of your box.

Even though you might feel skilled in the craft and do not anticipate any problems with box making, you might want to work through the cutting and soldering techniques prior to starting your box. We hope that you will pick up, at minimum, a few useful ideas.

Once the primers are completed to your satisfaction, you can then move on to the specifics of box construction. You will learn to square up the box sides, install braces and an inside shelf, hinge the box lid, attach a safety chain, and secure box feet. You will also become acquainted with advanced cutting and soldering techniques as well as how to care for a mirror and, just in case, how to repair broken glass.

While all of the procedures in the book are intended as steps in making the featured box design, you will be able to apply these skills to boxes of various sizes and shapes with any alternate lid designs you choose. This project is not particularly easy, so with its successful completion, you will have attained a reasonable level of stained glass skill.

In addition to average hand dexterity, you should plan to bring one other skill to the project: patience. Take your time; read all instruction details; be as precise as possible. If you are patient, you will be well on your way to completing a beautiful jewelry box.

Now, lets get started.

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A S YOUR INTEREST IN STAINED GLASS BLOSSOMS, you will discover that you are spending a great deal of time in your glass shop. You will want some creature comforts. Four elements greatly contribute to a comfortable and efficient shop:

• good light source
• sturdy work table
• nearby water source
• adequate ventilation

All aspects of stained glass making (cutting, foiling, soldering, and so on) involve a need for precision, and the better you see, the better the final product will be. A two- or four-bulb uorescent light hanging over a workbench is generally adequate.

A work table should be sturdy and at a height comfortable for the user. If you are of average height, a tabletop approximately 34 inches from the oor will probably work well. Plywood construction is ideal, and a size of 30 inches by 72 inches will handle most projects. The gray-colored work surface shown here is a piece of fire-resistant Homasote about 2 feet by 3 feet in size that can be placed on the plywood.

Homasote has a firm surface with a slight spring, which makes it perfect for glass cutting. (Plywood by itself is a bit rigid.) Pins and nails are easily secured in Homasote, and soldering is easier and safer due to its fire resistance. Homasote used to be readily available at all building supply stores but is no longer as common. You might have to call around to find it or settle for a substitute product.

In addition to providing the crafter with a handy place to wash up, a nearby sink will make it easy to clean the project at several stages. Any size basin can work, but one with an opening 12 inches by 20 inches or larger is ideal. Plan to use a screen strainer to prevent sand and other debris from making their way into your drainpipes.

Set up a shop in the area that is convenient to you based on what rooms you have available. You will only have so many options, so youll need to do the best you can with your space. Ideally, you will want a room with good ventilation so air can move through your work area during the soldering stage. If this type of setup is not possible, use a small table fan on your work table or purchase a smoke absorber, which is available at stained glass supply stores. You can also experiment with opening adjacent doors and windows to create a cross breeze in your work area.

In addition to the shop features listed on page 1, several other items will be very useful:

• bench brush and dustpan, for cleaning up glass shards and other debris
• storage bins for sheets of glass
• cabinet for chemicals and tools
• comfortable stool
• radio or CD or MP3 player
• multi-receptacle surge suppressor with LED light for operating several electrical items plugged in at once (the light will act as a visual reminder to turn off your soldering iron at the end of each work session).

STAINED GLASS SAFETY

Making stained glass is generally a very safe craft, and by adopting the safety precautions listed here, you will greatly reduce the likelihood of injuries and health problems.

• The most common injury that occurs in crafting stained glass is a cut finger. Prevention includes careful handling of the glass and frequent sweeping of your work area to eliminate shards and specks of glass.
• If you do get a cut, tend to it immediately by applying an antiseptic and adhesive bandage. Keep these items at close hand in your shop.

• Never eat, drink, or smoke while engaged in any of the steps in making stained glass items.

• Be careful and use common sense when working with lead cames and solder. Generally, stained glass crafters are exposed to only very low levels of lead while building their projects. Make sure to bandage any open wounds and thoroughly wash your hands after working with lead or solder.
• Wear closed-toed shoes at all times to avoid glass injuries to your feet.
• Do not allow children or pets in your work area.
• Use rubber gloves when working with patinas and etching cream. These substances can cause chemical burns on exposed skin and be harmful if absorbed into the bloodstream.
• Always wear safety glasses when cutting or grinding glass.