How To Build A Window For A Backlit Space
![Picture](/uploads/2/5/2/6/25267623/3017778.jpg)
To build a window to fit a backlit space, we first measure the space and draw the pattern. Then we cut off 1/4" all around so the piece will fit when it's completed.
![Picture](/uploads/2/5/2/6/25267623/4997520.jpg)
We built the panel and left 1/4" of free space when we soldered it so that we could easily apply 1/4" zinc outer bar to the piece. (the 1/4" Strip fit's over the glass 1/8" and adds 1/8" so the panel is just the right size)
![Picture](/uploads/2/5/2/6/25267623/3604885.jpg)
I took two pieces of zinc which were longer than the panel and nailed them in place.
![Picture](/uploads/2/5/2/6/25267623/961080.jpg)
Then I laid two small pieces across the spaces and marked where they needed to be cut.
![Picture](/uploads/2/5/2/6/25267623/8962709.jpg)
We use a Jarmac saw in our studio to cut zinc. It's preferable to a hack saw.
![Picture](/uploads/2/5/2/6/25267623/3510718.jpg)
I nail them all in place and then tap the ends that overlap so they will be lined up to the edge. This way, I only have to cut off the overlapping pieces on one end.
![Picture](/uploads/2/5/2/6/25267623/8379377.jpg)
I solder the outer bar at each corner and bring all interior lines to the edge of the zinc.
![Picture](/uploads/2/5/2/6/25267623/383231.jpg)
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.
![Picture](/uploads/2/5/2/6/25267623/9329128.jpg)
Then I take the panel and check it to make sure it fits the opening. It's a little long and just a slight amount too tall.
![Picture](/uploads/2/5/2/6/25267623/7804082.jpg)
So I take it over to the edge belt sander.
![Picture](/uploads/2/5/2/6/25267623/7575494.jpg)
So I take it over to the edge belt sander.
![Picture](/uploads/2/5/2/6/25267623/7931294.jpg)
And I sand a small amount off of the top.
![Picture](/uploads/2/5/2/6/25267623/4890798.jpg)
Then I check to make sure the panel fits the opening.
![Picture](/uploads/2/5/2/6/25267623/2337628.jpg)
Next I mark some copper for a frame edge.
![Picture](/uploads/2/5/2/6/25267623/8649986.jpg)
I cut it with tin snips.
![Picture](/uploads/2/5/2/6/25267623/5888260.jpg)
Then line it up with the edge of the panel and cut it to length.
![Picture](/uploads/2/5/2/6/25267623/5876885.jpg)
After tack soldering both top and bottom pieces, I mark an end piece to fit and tack solder it in place.
![Picture](/uploads/2/5/2/6/25267623/8013187.jpg)
When I have all four pieces in place, I solder the edges in place firmly and then I cover the copper with a thin, smooth, layer of solder.
Funny to cover the copper when we'll be adding copper patina to the panel, but I want it to match the rest of the piece.
Funny to cover the copper when we'll be adding copper patina to the panel, but I want it to match the rest of the piece.
![Picture](/uploads/2/5/2/6/25267623/4201076.jpg)
When it's done, the edge looks very smooth. We clean it with window cleaner and kwik-clean to prepare it for patina.
![Picture](/uploads/2/5/2/6/25267623/7251156.jpg)
Then we flood the panel with copper patina. Flooding it allows it to stay copper. If you don't apply enough, it tries to go black.
![Picture](/uploads/2/5/2/6/25267623/2265094.jpg)
Jeanne uses a little piece of rag to spread the copper patina around. She'll throw it away after she's done with it because patina dissolves rags.
![Picture](/uploads/2/5/2/6/25267623/5097614.jpg)
Then she cleans it with Kwik-Clean again to neutralize the patina.
![Picture](/uploads/2/5/2/6/25267623/613218.jpg)
She applies polish and lets it dry on the panel and then she buffs it hard with a soft cloth.
![Picture](/uploads/2/5/2/6/25267623/3048204.jpg)
There is glass in the panel that allows too much light through and the light from a bulb "burns" through the glass.
![Picture](/uploads/2/5/2/6/25267623/9015346.jpg)
So I put it in the sandblast cabinet and shoot a light coat of sand to rough things up on the back of the panel. There is a layer of contact paper on the front to protect it from the sand.
![Picture](/uploads/2/5/2/6/25267623/3805396.jpg)
You can see here how rough it looks.
I didn't solder the back of these panels, but in the future I won't skip this step. It makes the window stronger.
I didn't solder the back of these panels, but in the future I won't skip this step. It makes the window stronger.
![Picture](/uploads/2/5/2/6/25267623/5793010.jpg)
Look at how that small amount of blasting cuts down on the "burn through" of the light.
The panels are installed using some small screws and the windows look great!