This tutorial is courtesy of Glass Patterns Quarterly magazine
and was originally featured in the Fall, 2001 issue.
Design by Bev Diaczuk, Fabrication and original text by Dave Burnett

You can get a copy from Glass Patterns Quarterly of this project and pattern in PDF format by right clicking the links here and then either open it or save it. You will need Adobe Acrobat Reader to view the PDF version. A list of materials and suggest glass colors follows the instructions.

Start by making two copies of the original pattern. One copy will become your pattern pieces, the second copy is used as layout guide for putting together the panels. On the pattern copy, mark the glass grain direction, if any, and number each pattern piece. Cut the pattern apart using copper foil shears.

1. Position the paper pattern pieces on the glass paying attention to the grain lines you may have drawn. Score around the pattern. When scoring the glass, hold the cutter in an upright position and apply firm, even pressure.  Remember you are making 8 panels and need to cut 8 of each pattern piece!

2. Use breaker / grozier pliers to run the scored lines in the glass and remove the waste glass from the pattern pieces. A glass grinder can be used to smooth any rough edges and to shape the cut pieces if needed. 

3. Using 7/32" copper foil, hold the glass piece in a vertical position. Press the sticky end of the foil onto the glass edge, leaving the same amount of overhang on either side and wrapping the entire piece. Burnish the foiled pieces using a fid or lathkin. This smoothes the edges of the foil and adheres the sticky side of the foil to the glass. Place the foiled pieces on the layout copy. Hold in place with layout blocks and pushpins. Layout blocks help keep your panels the same size.

4. Apply flux to the copper foil lines using a flux brush. Solder all 8 panels, front and back. Soldering takes practice. A good iron with a rheostat will help in the soldering process. Once the 8 panels are completed, lay them on the work table side by side. Using black electrical tape, tape them together at the top and bottom. 

5. Pull the sides up to form the cone shape and tape together. Tack- solder at the top and bottom. Run a flat solder bead on each seam to hold the shade in place.

6. Tin the brass vase cap before soldering it to the top opening of the shade. This will firm up the shade so that the tape can be removed. 

7. Turn the lamp over and finish-bead the inside seams. Tack a piece of 16-gauge wire around the bottom of the shade and finish-bead with solder. 

8. Attach the shade to a lamp shade positioner. This will help control the angle when finish-soldering the outside seams. Solder the edges of the leaves used as overlays with a rounded bead of solder before soldering them to the stem of the flower. 

Clean the project thoroughly with flux remover and warm water before applying black patina. Clean the shade again and apply a glass polish to prevent oxidation. 

Place on base, light, and give yourself a hand!

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