You can make 3D items or sun catchers, they make great gifts.
Step 1: Gathering Materials
-A pattern (find one on the internet, alot of times i can't find one so i use simple children's coloring pages for a pattern, or you can just draw your own)
-Safety glasses (glass goes everywhere)
-Gloves (optional- i dont use gloves but i also cut my hands when doing this)
-Glass (you can even use mirror if you like)
-Copper Tape (i use 1/4 in thickness)
-Solder (50% Lead, 50% Tin)
-Glass Grinder (you can do without one but it is easier and makes edges cleaner)
-grozing pliers (these or ones specially made for glass)
- Glass Cutter
- Flux Brush
Step 2: Get Pattern
With your sharpie, trace the pattern on your glass. For dark colored glass i use white out to trace it.
Step 3: Cut Out the Shapes
-If you traced pieces on the same sheet of glass then separate them.
-When you cut glass, you want to try to cut it in a straight line. If your glass is textured then cut on the nontextured side, if it is textured on both sides then cut on the smoother one.
- If you want the result to be the same size as your pattern, then cut right inside the lines. I normally cut on or a little out of the lines so it can be ground down later to fit better.
-The glass cutter just scratches the surface. If you are cutting out a big piece then you can put the scratch over the edge of the table to break it. If it is a small piece then use your grozing pliers to take off the excess glass. The edges dont have to be perfect if you use a grinder. If you dont have a grinder, then use the grozing pliers to clean up the edges. Look at the picture to see how the grozing pliers should be held. If you hold them the other way then you have a good chance of shattering your glass.
- If you have a glass grinder then this will be easy. Make sure before you start that you put water on it because it needs to be wet. if it dries out a little during shaping the glass then add more water.
-Now just grind down the edges to the size you want (make sure your pieces fit together almost exactly, if they aren't then grind them down so they are).
- Once you have them all smoothed out, just clean them up with some water. Should take off the wet ground glass and the sharpie/whiteout lines. make sure you dry the pieces well.
Step 4: Add the Copper Tape
-Measure the tape you need before you rip it off the roll because you want to use only one piece. Make sure you have some to overlap a little.
-Put the glass in the middle of the tape and wrap it around the edges. You are going to want to make it stick well.
- I rub the edges on a table corner
- Push the tape down over the corners to frame the glass. Then rub that with a sharpie or the side of your nail (just to make it stick and not rip)
Step 5: Soldering!
Ventilation, because any fumes you inhale can't be good.
- Use a soldering iron made for lead soldering...not the electronic soldering iron.
- Use nails to hold your pieces in place
- Brush flux on before you solder. Dont flux the whole thing at one time, do it in small areas. If solder isn't melting and you turned up your iron then add more flux.
- Solder- Just solder over all the copper, its up to you if you want it very flat or want a puffy edge on it.
- Solder Both sides of the glass
- If you are making a butterfly or something and want to add antenna or want to add a hook to something, copper wire works best just add flux and solder. if its not copper, then add the tape first
Step 6: Clean It Up
Step back and admire your work :)