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The process of repairing these
stained glass panels requires
that the craftsmen not only restore
historical artifacts but also that
they record history.
Thesepanels were
taken apart, cleaned and recamed (the lead between the individual
pieces of glass were replaced). Seldom does this need to be done.
It is a very expensive process. There are tests that can determine
if the lead came needs to be replaced. Usually the stained glass
panel can be restored in place.
 Even before
the windows are removed
from their apertures, they are
photographed in situ with both
color and black and white film
in transmitted and reflected light.
These
photographs
document the
colors,
intricate
lead lines,
and the
damages
to the
un-restored
panels.
This
process is also repeated after
the studio restoration is complete.
When these windows arrive
in the studio, artisans
photograph the extracted panels prior to making rubbings
with hard wax blocks on rag
vellum. These rubbings are
marked with specific notations
about previous repairs, including
any lamination, plating, unstable
paint, silver stain, etc.
The panels are then dismantled;
some are so frail that they fall
apart in the artisan’s hands.
Next the pieces of tinted and
painted glass, sometimes hundreds
in a single panel, must
be cleaned. Removing crusty
residual weatherproofing
sealant from the glass usually
requires that the craftsmen assemble
the pieces on large,
shallow cookie trays and deluge
them with methylene chloride.
A skilled artisan
rebuilding window panels.
The artisans are meticulous.
They hand wash and carefully
inspect each piece on a light
table
looking
for damages
or
loss of detail. Glass
that has
shattered
and cannot
be repaired
is
expertly
replaced
with
newly
painted and re-fired glass, with
painstaking attention to assure
an exact match. Following the
pattern of a second working
rubbing, artisans cut and bend
new lead came in which to seat
the glass. With the glass in
place, they solder the joints.
This process is repeated as they
follow the third and fourth
layers of rubbing patterns until
the window is finished. To seal
the glass and lead came, they
smooth in a waterproofing
compound, tinted gray to match
the lead. This multi-phased
project spanned a number of
years and resulted in about
3,000 sq. ft. of stained glass restoration
and a commendation
from the Army Corps of Engineers.
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