Window Piece Replacement

by Bob
(Milwaukee, WI)

How to you replace a broken piece of glass in a leaded window??? Is there any special technique for undoing the putty within the came channel?? It seems easy enough to take the broken pieces out but how do you get the new piece back in??

Answer

Hi Bob,

If you can get the window out, remove it and work on it on a flat surface.

The way we do most repairs is to find the most direct path to the broken piece, then cut through each solder joint leading to it (both front and back). Once the solder joints are cut, you can pull the panel apart just enough to remove the broken glass and insert the new glass.

We usually use a small screw driver to dig out the old putty. If it's rock solid and won't budge, put some ammonia on it and let it set for an hour or so. The ammonia should loosen it up enough to allow you to get it out.

Once the new piece is in place, push the panel back together. Tap the edges of the panel using a straight piece of timber and a hammer, to get the joints tight. Resolder the joints, putty, and the repair is done. Remember to measure the panel before you pull it apart, so you get it back to the same size when you're done with the repair. Also, it's easiest to work on a work surface with 2 framing boards, like you use when you construct a panel. It helps to secure the panel when you're pushing and pulling on it.

If you can't get the panel out, you can cut the lead came, around the broken piece, diagonally in each corner, on the back side of the panel. Fold the lead back, remove the glass and putty, replace the glass and fold the lead back in place.

It sounds easier in theory than it really is. Sometimes the lead won't fold back, sometimes it breaks off or gets twisted. If any of those situations take place, you can peel the lead off altogether, on the back side. Next, you can either foil the new glass and run a solder bead on the back of the panel, or, peel the face off one side of a new piece of lead, cut it to fit and solder it in place.

Soldering in an upright position is not easy, but it can be done. I don't have any tips on the best way to do it, other than to cover the lead below the area you're working on so the solder won't drip down on it.