Making the Window
West Window
St. Stephen’s Chapel
St. Stephen’s Catholic Cathedral
Brisbane QLD
The Construction Process
Begun in May 1998
Full size drawings for the proposed new stone armature were provided by the architect. Utilising these drawings, masons carved the new stonework, and we constructed the new stained glass window. Accuracy in construction from both the masons and our team of glaziers was crucial if the panels were to fit into their allocated apertures.
A group of dedicated craftspeople working in a cooperative and sharing a studio located on the outskirts of Byron Bay NSW were chosen to undertake the work. The project team included:
Artist/Designer, Painter & Project Manager – Lance Feeney;
Studio Manager and Glazier - Arlee Bryant;
Glazier and Installation – Helen Fawell ;
Firing & Kiln-work – Trish Magee, Katie;
Waterproofing – Soji Bryant.
The Cartoons
Charcoal cartoons (full sized drawings) for the proposed panels were drawn up from the scale sketch, including the position of panel joins and supporting ‘saddle bars’. The lead lines were drawn onto the drawing in ink. Cut-lines were traced from the cartoons for glass cutting and glazing. Heavy grade tracing paper was used.
Choosing and cutting the glass
To assist colour choice and overall balance within individual panels and throughout the window, sheets of plate glass (approximate to the sizes of the individual panels) were put up on wooden easels, after being painted with black poster paint (on the reverse side) to simulate the proposed lead lines. The individual pieces of cut glass were then affixed to the plate glass using small balls of plasticine. This jigsaw/mosaic like process, enabled colours and tonal variation to be balanced under optimal natural light and provided opportunities for glass to be replaced before the painting process was undertaken. The choice of glass is critical and much care and time was devoted to ‘getting it right’. In some cases, whole areas of drapery, background or borders were re-cut. This became necessary due to the innate difference between the transparency of glass and the opaque nature of paint on paper. What works in water-colour, may not work in glass.
Painting and firing the glass
The next stage in painting each panel was to remove the individual cut pieces of glass (those requiring painting) from the easel and trace the main outlines - with the glass laid flat. The painted glass was then loaded onto kiln shelves and fired at 1250 degrees Fahrenheit.
After firing was complete, the glass was removed from the kiln, sorted, inspected and then re-applied to the transparent plate glass panels using drops of melted bees wax. This process is called ‘Waxing Up’.
The glass panel was then placed onto a vertical easel and a process of matting performed – i.e.. This process of applying a thin wash of glass paint to the surface of the glass, blending the paint and removing areas of paint to produce highlights and shadows, is called ‘matting’. It allows the artist to control the amount of light transmitted through the glass and modifying transparency.
Matting completed, the glass is again taken down from the easel and fired. The process is repeated until the desired effect has been achieved.
Fabrication
The painted glass is then leaded-up, soldered, waterproofed, polished, banded with copper tie wires and readied for fixing.
Fixing
The 37 crated panels, together with equipment and tools for fixing the window were transported to the Cathedral site in Brisbane. The window was located 3.0M above the Chapel floor and scaffolding was erected internally and also externally. Both sides of the window needed to be accessed for panel placement. Masons drilled holes in the new stonework to hold the supporting Saddle Bars.
Beginning from the base of the window, panels were checked for size against the new stone apertures and placed into their respective positions.
Panels correctly placed and aligned, copper tie wires were then secured to the saddle bars – ‘Banding’. The remaining external gap in the stone glazing grove was mortared to waterproof the window and the scaffolding removed. Fixing the window took four days. |