Getting started: Once all of your stained glass pieces fit snugly, you are
ready to foil and solder. You don't need any space between foiled pieces, but
can easily fill gaps with solder to up 1/8". And conversely,
you don't want your pieces squeezed tightly together, this can cause stress, and
when you heat the stained glass, too much stress can make your glass
break. Clean each stained glass piece of any
grinder dust or cutting oil and wrap with copper foil. Assemble pieces together
on a flat, heat resistant surface.
Using a flux brush, apply a small amount of flux to each joint and "tack
solder". Tack soldering is applying a small amount of solder to each joint
so that your pieces are held in one place.
Next, apply a light, even coating of flux to all seams. Too much flux will
spatter and create small pits or bubbles in your solder seam. Too little flux
will leave irregular solder seams and uncovered foil.
Basic soldering techniques:
Heat iron to a temperature that melts the
solder you are using to a liquid state (approximately 700 degrees). Remember to
periodically wipe your iron tip on a water-wet sponge. Grasp your iron the same
way you would hold a knife; fingers curled around one side of the handle, thumb
on the other. The tip of the iron should face so that the wide flat sides face
side to side and the thin sides face up and down. Hold the solder comfortably in
the other hand with approximately 6" uncoiled.
If you are holding the iron in your right hand, it will be easiest to work
right to left. If you are holding the iron in your left hand, work left to
right.
Begin soldering approximately 1/4" from the edge of your piece. Here is
where a small amount of coordination is required. Feed the solder against the
flat side of the tip and lightly touch the iron to the copper foil seam. You
should hear a little sizzle and see the solder puddle under the iron tip. Move
the iron slowly and smoothly across your copper foil seam at the same time you
feed the solder against the tip.
Watch your solder seam. If it's flat, slow down and use more solder. If it's
pouring onto your stained glass, speed up. Good soldering takes patience and practice -
most people need to complete a few projects to get the hang of it. If you are
planning to use a U-channel came to edge your piece, leave abut 1/4" of
your copper foil seam free from solder at the edge of your panel. If you are
simply tinning your edges, complete the seams all the way to the edge.
If you are unhappy with the way your solder seam looks, don't keep going over
it. Move on and come back to it later. Too much heat in one place can cause your
stained glass to break. (Not to mention getting you frustrated!) Remember, you can
always re-flux and go back over these seams once they have cooled.
After you have completed one side of your piece, carefully turn it over.
Generally, you will hold your piece on the edges near the center. Turning your
piece over from the top can sometimes cause your piece to bend in the center.
The second side of your piece doesn't need to be tack soldered. Simply apply
a light amount of flux to the seams and solder as you did on the first side.