Fitting Into An Existing Opening

I am planning on making a sidelight window for our house 11 inches x 64 inches. Do I subtract 1/16 inch on all four sides or 1/32 inch on all four sides? I'm having some trouble figuring out how to make the pattern fit.

Is this measurement the actual size of the opening that the panel will be installed into? If so, subtract 1/16 inch off each edge or basically subtract 1/8 inch from both measurements (10 7/8 inches x 63 7/8 inches). Before you start cutting out the glass for this panel, take a closer look at the opening it will be installed into. Take lots of measurements both horizontally and vertically at the edges and through the middle. It is not uncommon for an opening to have many different measurements; After all, if the original window didn't fit into the opening, someone just had to go back and either sand or route out problem areas until it did fit.

How will you edge the window? Will you use a flat "U" channel, adjustable "U" channel, an "H" channel? In lead, zinc, brass, or copper? Delphi recommends flat "H" lead; 3/8" and 1/4" are common sizes. Adjust the measurements of the panel based on the depth of the channel you select, measuring from the outside edge of the came to the inside of the channel that the glass will be inserted into. For instance, if the depth is 1/4", you will need to adjust all 4 sizes by 1/4". The reason flat "H" lead is best is that not every window opening is exactly square. While installing the finished glass panel, you can trim off the portion of the "H" channel that is in the way. When using the hard metal came, the edge came would have to be removed, the glass removed, re-cut or ground, re-foiled or cemented, and the edge came soldered back into place.

Now, look at your different dimensions and adjust them accordingly, then go back to your drawing board and adjust your panel. Delphi suggests drawing in two lines, both horizontally and vertically, to divide the design in half both ways. Divide the dimensions in half and measure from the center lines to make a mark for where the design will end. Draw in the final edge lines and your pattern will be ready for glass assembly.

Installing a stained glass window in an existing opening (window) in your home can be relatively simple. The directions that follow assume that an important step has been followed: that the stained glass panel was made from a template of the window it is intended to fit. Since it is almost a sure thing that the window is not square or geometrically perfect, an accurate template is essential for making a panel that will fit properly.

For larger window, pieces of 1' x 2' boards can be used as stops to hold the panel in place. For smaller panels a simple corner molding will work. Cut the boards to fit the opening from corner to the next. Again, because the window is very likely not square, mark each piece's position, since one cut for the top will not fit the bottom. Miter the ends to fit.

If the boards are to be finished, now is the time to do it Set the stops in place behind the outer glazing or window glass and screw. Be sure this outer pane is thoroughly cleaned. You won't be able to clean it once you set the stained glass in place. Also, clean the stained glass panel. Set the panel in place against the stops and secure it temporarily with scrap wood. Remove the scrap one piece at a time as you place the finished stops in place. If necessary you can use an inner layer of protective glazing by following the same procedure described above.


Tuesday, July 17, 2018
4 Posts



Tuesday, June 12, 2018
91 Posts

@ There are several approaches to installing glass art into cabinet doors, but most frequently the doors are designed with a routered channel on the reverse to fit the glass art. Stained glass panels should be finished with a soldered or came border, then inserted into the opening and secured. Methods for securing the panel can include using clear silicone adhesive, which will prevent panels from rattling, but makes it difficult to remove and change panels later, or using retaining buttons or cabinet door clips which are affixed to the wood door with a screw and press the panel into the frame gently. These hardware options are available at Delphi, and should be positioned around the border of the frame so it captures your art from all edges.