The process starts with scale drawings.  Typically several  drawings are developed and one is chosen for execution of the project.

Stained Glass Design, Fabrication, Restoration, & Repair - Johnson County Stained Glass - Kansas City - Estb 1982

Installed Closeup.

Floating borders are highlighted by Copper metal came and the deep right angle cutouts in the blue background. Purple streaks in the blue background flow continuously across subject matter elements    (pink clouds & black "fractures"). Round Cabochons highlight centers of the planets and center of open background space. - Fractured Space II

Assembly continues with lead and copper cames. Another of the delicate black "fractures" is ready to be fitted into the panel.  Top half of the copper channel is in place to be marked for cutting. The lead came is cut with either a sharp knife or a lead dyke. The copper is cut on a table saw.

Assembly complete.

Installed into Garage Gable

Lead came is a soft metal and can easily be bent and cut by hand.  The copper "came" used in this window is a very hard, stiff metal. A small metal roller is used to bend the copper to the precise radius required.

Here, assembly or "glazing" is underway. Typically, stained glass windows are assembled using lead channels holding  the pieces of glass together.  This piece features the use of wide copper channels in addition to the traditional lead channels (aka lead "came").

Here, cutting is complete with the exception of the white cloud band across the center which was replaced by a mottled pink and white glass in the final assembly. Shown below is one of the very delicate black "fractures" featured in the piece.

Here, cutting is progressing with the addition of "planets" and clouds to the floating border pieces

This picture shows the white paper pattern pieces being arranged on the sheet of glass that will be used for the background. The patterns are arranged as they are positioned relative to each other  in the design. Cutting then results in the grain of the background glass being in register and flowing continuously across the piece (universe :) ).  The result can be seen in the next picture below.

The scale drawing is next worked up to a full size working layout. Three copies are made. One copy is cut into patterns for each piece of glass. A second copy is used to lay the cut pieces on to keep them in place.  The third copy is used later, as a build pattern, to keep pieces in place during assembly.  Picture at left shows the full-size layout with glass cutting underway.  This window measured roughly 40"x18".

fractured space II

from start to finish

Progress pictures from initial drawings thru cutting, building and final installation.

Design, Glass Selection, Cutting, Assembly, Install by Steve Daley