February 2007 Soldering A Zinc Edge On A Panel

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With the new year started I like to look for ways to improve and this month I've been listening to a book on CD.  "Success Is A Choice" by Rick Pitino, it's very inspiring and points to ten steps that will  help us achieve success in business and in life.


This month we've been trying to solve the breakage problem that occurs sometimes when shipping glass. We keep trying and hope to come up with a solution.
 
A common skill that stained glass artists need to develop is that of how to apply 1/4" zinc outer bar to their windows. 
 

Soldering A Zinc Edge On A Panel

Many times we solder zinc 1/4" outer bar onto a window as a framework to strengthen it. Raw glass panels are usually very weak but adding zinc really increases their strength.

”solder

To do this, I like to take two pieces of zinc which are longer than the panel and nail them in place so that the glass is locked between the channel of the two pieces..

”solder

 Then it is easy to lay two other pieces across the edges that are not yet enclosed in outer bar. I can then mark them where they need to be cut.

”solder

 We use a Jarmac saw in our studio to cut zinc. It's preferable to a hack saw. We took it to a machinist to replace the aluminum parts for brass parts that work better.

(If you're handy you can save money by getting a mighty-mite from HarborFreight.com but you have to check that blades fit..don't use the ones that come with it for cutting zinc, order Jarmac Brand replacement blades for the saw from the same source you get your metal from.

”solder

 I nail these pieces in place and then tap the ends of the zinc that overlap the edge so they will be lined up to the edge. This way, I only have to cut off the overlapping pieces on one end.

”solder

 I solder the outer bar at each corner and bring all interior lines to the edge of the zinc.

”solder

 Then I cut off the extra zinc, using the saw blade as a "guide" to keep the window lined up with the edge of the panel. 

The window is now ready to have rings soldered to the framework or to be installed in another manner.
In following your instructions, if I'm correct, you will be left with a small area at each corner (side view) where the glass is exposed. At times I overcome this by mitering the corners but that can be tiresome. When I've used your method, I've put a bit of copper foil on the corners prior to applying the edging and then I can fill in the "hole' with solder.
Is this the proper way to do this or is there a better way to handle it?
-Georgia


What I do is solder the holes closed. I don't find that I need to seal it with copper foil, I just hit the hole with an iron tip that has a bit of solder on it. The quick pass builds a bridge of solder that I can come back and seal with a bit more buildup after it cools.
-David

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Email:  david@gommstudios.com

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