Art Nouveaux Case Mod, Part 4

Glass Windows

With so much effort put into carved wood, I want a side window that harmonizes with the rest of project. Using the dogwood blossom design, a leaded-glass window will fit into the lip carved out behind each of the side panel openings.

[caption id="attachment_457" align="aligncenter" width="300" caption="Trim a piece of paper to fit in the rear opening and then trace around the edges of the openings."][/caption]

To start, a paper template is cut to fit the opening and held in place with tape. From the outside, the openings are outlined on the paper and a rough sketch of the blossom design added. A more detailed drawing is then made on the paper using sharpie markers to suggest the positions, shape and layout of the glass. For this window, a rectangular grid will be imposed over the dogwood design
to emphasize the window aspect.

[caption id="attachment_459" align="aligncenter" width="300" caption="The pink glass used for the dogwood petals, has a slight iridescence on one side. Stakes in the glass are oriented to radiate from the centers of the blossoms as much as possible."][/caption]

[caption id="attachment_460" align="aligncenter" width="300" caption="Copper foil is used to wrap the edge of the glass, and then the are segments tacked in place with a tiny blob of solder."][/caption]

[caption id="attachment_461" align="aligncenter" width="300" caption="Branches are added to connect the flowers."][/caption]

[caption id="attachment_462" align="aligncenter" width="300" caption="Clear glass that has a "frost" texture is cut and fit for the rectangular panels. "][/caption]

 

Petals of pink glass are cut and shaped for the blossoms, caramel brown for the branches, and a clear frost pattern for the background grid. Copper foil is wrapped around the edge, and then the individual pieces are tacked together with a bit of solder at points where they touch.

 

[caption id="attachment_464" align="aligncenter" width="300" caption="A heavy-duty soldering iron is used to flow solder across all of the foil-taped edges and fill small gaps."][/caption]

Once all of the pieces have been cut and placed, a heavy duty soldering iron is used to flow tin-lead solder over all of the exposed copper foil on both sides of the window. (This also lets me conceal all of the small gaps that we amateurs leave when attempting this type of work.) Brass plated furniture tacks are soldered to the center of the blossoms and then the window is scrubbed clean before mounting into the side panel. Several small wood screws with washers hold the window into the wood frame, then the metal side panel is again attached to the wood panel.

 

[caption id="attachment_465" align="aligncenter" width="291" caption="With the bench light shining in the rear of the case, the mounted window is viewed for the first time. "][/caption]

The second case window was assembled by the same process, starting with a paper template that fits inside the recessed opening on the back of the wood panel. The edges of the panel openings are marked and a flowering dogwood design is roughed out on the paper.

Glass pieces are then cut and ground to follow the resulting design, with pink for the blooms, caramel color glass for the stems, and clear frosted for the background. All pieces are edged with thin copper foil and tacked into place before the final soldering. Using a heavy-duty soldering iron, tin-lead solder is used to cover and bond the segments together into the assembled window.

 

[caption id="attachment_466" align="aligncenter" width="300" caption="The second window seems to assemble quicker, (practice makes perfect?) this time, with a stylized branch pattern in the clear background."][/caption]

Textured furniture tacks are used to cover the small openings at the center of the petals and suggest the dogwood blossom detail. The finished window is cleaned and installed into the wood panel, held in place by several screws. The metal side panel is attached to the completed wood panel with wood screws.

 

[caption id="attachment_467" align="aligncenter" width="300" caption="The finished panel is reversed and test-fit in the rear opening of the side panel. Wood screws with washers hold the panel in place."][/caption]

 

[caption id="attachment_469" align="aligncenter" width="300" caption="The metal side panel is reattached to the wood panel."][/caption]

[caption id="attachment_470" align="aligncenter" width="300" caption="The galvanized steel of the case blocks most light coming from inside the case. This side will need its own light source."][/caption]

 

Next time: Decisions about cooling