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Student Material 001: Cold Glass Techniques Quick Reference

Material ID: U12M2-MAT-001

Glass Scoring Reference

Parameter Recommendation Notes
Cutter type Carbide wheel, self-oiling Steel wheel acceptable for beginners
Cutter angle 90° to glass surface Some cutters designed for slight tilt
Pressure Firm, consistent — faint scratch sound Too hard = chips; too light = incomplete score
Passes ONE pass only Never retrace a score line
Direction Edge to edge, continuous motion Never stop mid-glass
Oil Light cutting oil or kerosene Reduces friction, extends wheel life

Breaking Methods

Method Tool Best For
Running pliers Running pliers (flat jaw with center line) Straight scores, long cuts
Grozing Grozing pliers (serrated jaw) Curved scores, nibbling excess
Table break Table edge + hand pressure Simple straight cuts (less control)
Combination pliers Breaking/grozing combo General purpose

Grinding Grit Progression

Grit Purpose Surface Finish Use Case
80-120 Rough shaping Coarse, visible scratches Removing excess glass, initial edge shaping
220 Smoothing Fine scratches visible Removing 80-120 grit marks
400 Fine finishing Smooth, slight haze Lead came preparation
600+ Polishing Near-clear edge Decorative exposed edges

Note: For copper foil work, 100-grit finish is preferred — micro-texture improves foil adhesion.

Copper Foil Specifications

Glass Thickness Recommended Foil Width Overlap Per Side
2mm (thin) 3/16 inch (4.8mm) ~1.4mm per side
3mm (standard) 7/32 inch (5.6mm) ~1.3mm per side
4mm (thick) 1/4 inch (6.4mm) ~1.2mm per side
5mm+ (heavy) 5/16 inch (7.9mm) ~1.4mm per side

Foil backing options: - Copper-backed (standard) — for most applications - Black-backed — for dark/opaque glass where copper color would show through - Silver-backed — for mirror or light-reflective glass

Foil Application Checklist

  1. Clean edges with isopropyl alcohol
  2. Dry edges completely
  3. Peel back 2 inches of foil backing
  4. Center foil on glass edge
  5. Press onto edge, wrap around corners smoothly
  6. Overlap start point by 1/4 inch
  7. Burnish with fid — press flat on both sides
  8. Check: no wrinkles, no gaps, no bubbles
  9. Tug test — foil should not peel easily

Soldering Reference

Parameter Specification
Solder type 60/40 (60% tin, 40% lead)
Iron temperature 700-800°F (370-425°C)
Tip type Chisel, 3/8 inch wide
Flux Oleic acid (liquid, stained glass formula)
Bead profile Slightly convex, smooth, even width

Solder Joint Troubleshooting

Problem Cause Fix
Solder beads up, won't flow No flux or oxidized foil Apply flux, re-solder
Solder runs through gap Pieces not tight together Reassemble, tack, re-solder
Dull, rough bead (cold joint) Iron too cold or moved too fast Reheat with flux, re-flow
Black residue (burned flux) Iron too hot or lingered too long Clean, reduce temperature or speed up
Glass cracked near joint Excessive heat transfer Use faster motion, less dwell time
Bead too flat Too little solder fed Feed more solder wire
Bead too high/lumpy Too much solder or too slow Move faster, reduce solder feed

Lead Came Reference

Came Profile Cross Section Use
H-came H-shaped Interior joints (glass on both sides)
U-came U-shaped Panel edges (glass on one side)
Round Round top profile Decorative interior lines
Flat Flat top profile Traditional, lower profile
Came Size Channel Width Best For
3/16 inch ~3mm Small panels, delicate work
1/4 inch ~4mm Standard panels, most applications
3/8 inch ~5mm Structural panels, large pieces
1/2 inch ~6mm Heavy architectural, large windows

Came Assembly Checklist

  1. Stretch came to straighten (pulling horse or vise)
  2. Cut came with came knife or saw (never scissors)
  3. Fit glass into channels — should be snug, not forced
  4. Solder all joints where came strips meet
  5. Apply cement under came flanges (both sides)
  6. Clean excess cement
  7. Allow 24 hours for cement to set before handling

Last Updated: 2026-03-19