Since most of us do not cut our glass pieces perfectly, we rely on one of two methods to shape our pieces: using an abrasive stone or an electric grinder.
TIP: Wear safety glasses to protect your eyes from glass slivers.
Using an abrasive stone: This method is most appropriate for light sanding on large pieces.
Similar to filing, this method is the most time consuming and also the most work. Holding your glass piece in one hand and the stone in the other, file the edge of your glass into the desired shape.
Using an electric grinder: This method is most popular because it is quick, efficient and easy to do. An electric grinder has a spinning diamond coated grinding head that is cooled by water. You simply lay your glass flat on the grinder's surface, push the edge against the grinder head and slide it around until it is the desired shape.
Whatever your method, the best way to fit your glass pieces together is to start at one corner of your project and work your way across. Lay your first glass piece onto the layout pattern and check for fit. Can you see the pattern lines all the way around this piece? If not, mark the areas that go over the lines with a felt tip pen. Lightly grind and shape your marked areas. Remember to grind a little at a time until you become familiar with your grinder. You'll be surprised at how fast glass grinds away. Lay it back on your pattern and check the fit against the pattern. If its too small, either cut the piece again or make up for the difference on the next piece. If you are using lead came, you'll want to recut your piece for a more exact fit. At any rate, as you work across your piece, it is more important to shape your glass pieces according to the pieces that surround them then to shape strictly as each piece looks on the pattern.
Tip: It is important to dry off your glass pieces after you grind them and before fitting them to your layout pattern. This prevents your layout pattern from warping.
Most of us do not cut or grind our pieces perfectly, so a little flexibility in your finished piece is recommended. Don't worry if you find some gaps between your ground pieces. After you solder your piece together, you probably won't notice where those gaps were. If you are using lead came, you'll want to be a little more precise - lead came is not as forgiving to gaps between your pieces.
