So we are finally getting around to posting the exciting details of our stained glass window installation… As you may remember from the previous posts the day started with removing the plywood that filled the openings for the last couple decades, letting the light once again stream into the living room! That was amazing but what was left around the window frame was not.
So we had to rebuild areas of the sashes with new oak that we milled on our router table to match the old. To make it curve, we soaked the wood and kerfed the back. Always a challenge but it turned out well. The wood stands out here but once we stained it, the new areas blended in nicely.
To create a new stop on the outside of the sash, we used new PVC trim for low maintenance. We precut and labeled all the trim so it would be ready to go.
The windows traveled from Buffalo, NY on these extremely sturdy plywood forms that Megan had built to our exact radius to construct the windows on top of. It was great to get double duty out of the forms. She then sat them on thick foam for additional padding.
And in went the first window! It fit perfectly on the first shot and we anchored it with glazing tacks.
We then installed thin oak spacers and did a real thorough cleaning of the glass since we won’t get another chance. You can see we are constantly dealing with curving everything, having to kerf the spacer.
The last step was to install the outer trim/ stop. We installed it in a thick bead of silicon. When finished the outer glass, trim, and sash will all the sealed together. The inner stained glass however will be able to breathe to the interior to prevent condensation between the panes.
For doing the work we set up scaffolding below the window, and Megan’s boyfriend Chris would very carefully hand the glass up to us.
There was not much of a ledge to support the outer pane on until we had the new stops in place. On the center window, the outer glass could also have been a little wider. We didn’t quite add enough to the arch length to account for the larger outer radius, but hey, how often do you order custom curved glass windows for your house? Either way we made it work.
With a few extra hands, the glass stayed in place and the trim went up locking it in forever.
And we were done… what a day! The culmination of months of design and endless hours of hard work by McElf cutting, grinding, bending, assembling, banding, and soldering every piece of glass in that window. Megan’s family and Kelly’s family were both there all day to watch the ‘exciting’ installation and celebrate the completion of this wonderful project with us… Cheers!