Replacing pieces with copper foil technique

by Kim Seibert
(Delaware, OH, USA)

Hello,

I read your tutorial on replacing pieces that broke...very helpful. I just had a question: I put a U zinc came border around the edges of my stained glass, and the three pieces I want to replace are all on the edges! Do you recommend cutting the U zinc at the corner, or using the soldering iron on the corners, or what?

And two of the pieces I want to replace are mirror glass - somehow the reflective backing got damaged. How does that happen? I made the piece just a few months ago, and it didn't get damaged until after I hung it up!

Answer

Use the same technique with the piece of aluminum to open the zinc. You'll need two pieces...open the front side of the corner and leave the aluminum in there to prevent run through from the back soldering it closed again. Turn it over and open the back side. Do the same all the way down the zinc until you are well past the broken pieces. You want to pull the zinc awayfrom the edge so you can get at the broken pieces. Repair them then put the zinc back in place and resolder.

The backing on the mirror was probably attacked by flux or it might have gotten scratched by something on the wall. I always spray the edges (most important) and backing of mirror with an UV Sealant after it's cut and before I assemble it in the project. The spray will protect the backing, and it prevents flux from getting between the actual glass and mirror backing which causes "black rot". I'm sure you've seen that in old bathroom mirrors.

You can find a tutorial on working with mirror Here