Stained Glass

There are 2 methods used in making stained glass panels: Lead channel (known as Came Lead) and the copper foil method. Examples of both types of stained glass products are sun catchers, windows, and lampshades.

Lead Came

While the Romans were not the first to glaze with lead, they were instrumental in spreading the practice throughout Europe and the Mediterranean. They produced their channeled lead by laying reeds side by side in a shallow pit. Molten lead was then poured into the pit covering the reeds. Once the lead had set, it was sliced into strips and the reeds were removed, exposing concave channels for the glass. The end product was called Calamus Plumbum, or Reed Lead. As the Roman influence succumbed to the Gaels in northern Britain, Calamus shortened to Caim. Later Caim was Anglicized to Came. It was in this way that Channeled Lead became Came Lead.

In this method the lead channel is used to hold the pieces of glass together. In forming a design, the came is cut where it meets another came at intersections in the design. These joints are soldered. The total visual effect of a leaded piece is one of areas of color viewed against a dark figure. As light filters through the glass, it silhouettes the came and clearly outlines the design. The Came is a soft, flexible material that conforms easily to the shape of the glass. When seen in cross-section, flat came resembles the letter H laid on its side. It has a crossbar down its middle, with 2 channels on either side. This crossbar, or heart, is approximately 1/16" thick and serves to separate from each other the pieces of glass that are fitted under the lip, or flange, of the came.

Lead came is available in a variety of shapes and widths. The most popular widths are 3/16", 1/4 ", 5/16", 3/8", 1/2", 3/4", 1" and 1-1/2". Flat came and half-round came are the most commonly used shapes. These names refer to the shape of the came seen in cross-section. There are also special-purpose cames - such as high-heart and U channel. The latter has only one channel and may be used to give a finished appearance to the outside edges of a stained glass piece that is not designed to be set into a molding.

Soldering Lead Came

Each lead joint (if flat came) is tapped with a small hammer so that it is as flat as possible for soldering. A wire brush is used to clean the joints of lead oxide (direct cleaning impedes solder flow). Flux is applied. The end of a piece of .125 50/50 40/60 solder is laid on the joint. A soldering iron is lowered down on the joint, melting the solder and bridging the two lengths to be joined. Solder will flow wherever the flux has been applied. One side is soldered, then the piece is turned and the other side is completed in the same way.

Copper Foil

Copper Foil was an innovation introduced at the turn of the century. Its development as a technique and its principle usage were in the manufacture of Tiffany lamps and executed in the Art Nouvean style. Because of its flexibility and its relative thinness, copper foil is better suitedto small pieces of glass that make up Tiffany lamps and Art Nouvean designs. Copper foil is available in narrow rolls that are adhesive-backed.

In this technique, the edges of each piece of glass are wrapped in foil. Each piece is then soldered to an adjacent one. Since small pieces can be used, many intricate designs can be produced.

Flux

Flux cleans came and foil, prevents oxidation, and causes solder to flow. It is applied prior to soldering.

Fry's Classic Stained Glass Products offer customers a complete line of material for either method of stained glass assembly. The versatility of 4 different solders - Classic Ultra Lead-Free, 60Sn/40Pb, and 63Sn/37Pb for copper foil work, and 50Sn/50Pb for use with came lead, ensure that all creative needs will be met. The high quality and purity of these products is essential for the stained glass industry. Fry's Classic 100 Gel Flux is a non-smoking, odorless product for use with copper foil and Classic 3200 paste flux works even on heavily oxidized came lead. Classic NeutraCLEAN neutralizes and removes flux residue from stained glass reducing the chance of oxidation on the surface of the metal. Classic Evershield, applied as a final step, protects solder and came lead while its natural protective patina is forming.