DIY Network

Flaming Heart Glass Wall Sconce This flaming heart glass sconce lights up a gloomy room. From "Craft Lab" episode DCLB-246

Guest Cathi Milligan joins host Jennifer Perkins and demonstrates how to cut glass pieces for her flaming heart wall sconce.

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Flaming heart glass wall sconce designed by Cathi Milligan.

Materials:

kiln with 13" interior minimum
ring saw
cordless hand drill
small hole saw
grinding bit
fusible glass sheets: clear, red transparent, amber transparent, red dichroic, turquoise dichroic, blue opaque
rubber cement
prints of the design for each color and sheet
sanding block for glass
glass glue
metal epoxy
glass hanging epoxy
four, 2" aluminum threaded posts
2" steel mending plate
4" steel mending plate
kiln shelf paper or kiln wash
lamp fixtures
picture hanger
flat container
water
light bulb

Steps:

Note: The design for the flaming heart project is comprised of glass parts that are fused together almost like a puzzle. Each part, the flames, the heart and the flowers are separate parts to be cut out before being assembled. Each layer of glass needs to have a representative sheet of paper printed out and glued to the surface for cutting on the ring saw. The heart and the flames get an extra sheet cut since they are backed with clear glass.

	Figure A
	Figure B
	Figure C
	Figure D

1. Determine which glass colors correspond with which designed sheet and adhere the paper design to the glass with rubber cement.

2. Once the rubber cement is dry the pieces are ready to be cut out. The ring saw's blade is encrusted 360 degrees with diamonds and can cut the glass in any direction. Water in the bottom bath section of the saw keeps the blade and the glass from getting hot and breaking. Patience is very important when cutting glass. Gentle pressure is applied as the glass is guided around the blade.

3. The flames have three design sheets, the heart is also from three design sheets and the flowers are from two design sheets, the leaves are cut from a single sheet. Put on your protective eyewear and start cutting (figure A).

4. Once everything is cut it will need to be cleaned and the edges of the glass need to be lightly sanded in water (figure B). This prevents the edges of the glass from fogging up when fused. Make sure the glass is clean and dry before assembling your glass for fusing.

5. Assemble the flaming heart design for tack fusing. The layers of the design are tack-fused together so that the glass pieces remain raised with texture — not fused smooth and flat.

6. Apply glass glue (figure C) in very small quantities to make sure the flaming heart pieces stay in place.

7. Once the glue is dry, the assembled glass heart design can be put in the kiln to fuse together (figure D).

Note: Some kilns have built-in programs for a tack fuse as well as full fuse, to use for fusing flat panels. If that is not available, check the fusing schedules for your kiln. The kiln program runs slowly and adjusts the temperature up through stages and holds until it reaches the target temperature and holds. Once that's achieved, you need to quickly cool down to about 1000 degrees and then allow the program to decline slowly, annealing along the way. Some kilns have peek holes to check fusing progress. Add more holding time for a softer fuse with less definition. After the quick cool down, allow the kiln to resume its program to a complete cool down. The kiln shelf (shelf glass will be sitting on) must be prepared for fusing beforehand. Coat the shelf with multiple coatings of kiln wash or cover with a piece of kiln shelf paper. The shelf paper will leave less of a mess, but if you are firing a piece in a mold it should be coated with kiln wash. These preparations keep the glass from sticking to the surfaces in your kiln. They also contribute to the look of the back surface of the piece. If using kiln wash, make sure it is completely dry before firing the glass. Moisture can result in glass breakage and damage to the kiln.

8. The flame heart will require the trimming of the fixture as well as the attachment of hardware that's been prepared while the glass has been cooling. Use a marker to indicate where the cuts will be. Mark the sides and the bottom area to be trimmed. Put on the protective eyewear and work gloves. Caution: The metal will be sharp right after it's been cut.

9. Trim off excess metal on the fixture at the ring saw. Avoid cutting the cord and electrical parts. Grind away the excess metal on the sides with the ring saw blade and use a metal file to smooth those edges. Clean and dry hardware before attaching.

10. Attach a picture hanger to the back of the fixture with two-part epoxy meant for metal. Two inch aluminum threaded posts are attached to two mending plates — one 2- and one 4-inch mending plate. These will be attached with the same epoxy that was used for the hanger on the fixture. The threaded posts allow the glass to be removed from the fixture to change the light bulb and clean the glass. The posts coordinate to holes that are on the fixture.

11. Drill the bottom holes slightly to accommodate the screws of the threaded posts. Attach the posts to the fixture to determine their placement on the mending plates. Mark the plates and remove the posts and epoxy them onto the plates.

	Figure E
	Figure F

12. When dry, the hardware needs to be attached to the glass with glass-hanging epoxy. Attach hardware to fixture and determine placement on the glass. Mark the glass (figure E) and prepare for the epoxy. Grind the surface slightly with a hand held cordless drill using a grinding bit in the area where the hardware goes.

13. Use the cleaner provided by the epoxy maker to clean both surfaces to be attached. The metal may require a couple of cleanings.

14. Apply activator to both pieces with the eyedropper provided and then adhesive to the hardware. Attach hardware (figure F) and check that placement is accurate before it sets up too much. Once perfect, allow to dry according to manufacturers instructions. All adhesives must be cured before light is assembled for use.

15. Check all connections before assembling the lamp. Screw in a light bulb before attaching glass to the fixture. Hang your flaming heart glass wall sconce, turn on light and enjoy!

GUESTS :

Cathi Milligan
Bead Brains
Website: www.beadbrains.com