Wear safety goggles at all times when working with glass and solder. Be sure to wash hands immediately after handling soldering materials.
Resources: All supplies for this craft are available at Manhattan Stained Glass.
- One 12-by-12-inch piece of 1/8-inch-thick glass -- any kind of slag (marbleized), tinted, or clear glass will do
- Glass cutter
- Cutting rail
- Glass pliers
- Scythe stone
- Quarter-inch copper tape
- 8-inch-long piece of 4-by-4 lumber
- Bone folder
- Soldering iron
- Solder (60/40)
- Black solder patina
- Rubber bumpers
- Windex glass cleaner
Cut the required number of glass pieces at the following measurements with a glass cutter. If all cuts are made correctly, you'll need just one piece of 12-by-12-inch glass.To cut successfully, align the glass cutter with the cutting rail on top of the glass and score (do not try to cut all the way through). Center the line indicator on the glass pliers with the score you just made, and squeeze handle to pop glass apart.Four 3 3/4-inch squares for sidesOne 3 7/8-inch square for bottomFour 2 1/8-inch squares for lid topFour 4 1/8-by-1-inch rectangles for lid sidesFour 1-by-1 1/2-inch pieces. Measure a half inch from the corner on one long side and cut from that point to the opposite corner on each, making a 45-degree angle. These pieces will construct the lid handle.
If necessary, file the edges of the cut glass on a scythe stone.
Wrap the edges of all the cut pieces of glass with copper tape. To do this, remove the paper backing on the tape and center the glass edge on the adhesive side. Push down the excess to create a 1/16-inch of overlap on the front and back of every side of each piece. Burnish tape with a bone folder to make sure it is securely affixed.
Using a 4-by-4 to hold the pieces at 90-degree angles as you work, solder all four sides together to make an open-ended box. To solder, first brush the wrapped copper tape with flux, then apply solder onto the tip of the soldering iron, and then brush the soldering iron over the tape where it will transfer. Practice this step on some scraps first.
Join the bottom piece to the box as you did for the 4 sides.
Solder the four lid top squares together in a grid to make a larger square. Complete the lid by soldering all four lid side pieces to the lid top. Add a handle by joining the four small handle pieces in the center of the top of the lid, with cut corners facing away from the center.
Using a Q-tip, apply patina to all soldered edges
Attach 4 rubber bumpers to bottom of container.
Clean the entire box and lid with Windex, and fill with Q-tips.