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Stained Glass Window

Stained glass and aquarium rocks are placed onto Plexiglas, and then grouted to make a beautiful window.

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Stained-Glass Window

Materials:

2 windows made from Plexiglas and old trim molding
colored aquarium glass
stained-glass pieces
wood trim
clear tub and tile adhesive
grout
aircraft cable
large scrub brush
sponges
straight edge
glass cutting wheel
silicon sandpaper

Figure A

Create your own design. Think about dividing the windows into different areas for the various materials being used. Flat stained glass verses rounded aquarium glass.

1. Once the layout is achieved (figure A), cut one inch molding to desired lengths.

2. Stain or paint the molding.

3. Using found stained-glass pieces, score the pieces with a glass cutting wheel on a hard smooth surface. Align the scored line up with the edge of the table, and then gently tap with the other end of the glass cutting wheel to snap-off the glass.

Tip: We found that it was faster and easier to work with shapes that occurred naturally while cutting down the glass pieces. Custom cutting each piece was a bit more timely and frustrating. Remember, errors can be corrected by the space occupied by grout. If you get a perfect cut except for a little nub, try using silicon sandpaper to smooth the edge.

4. After you have reached the perfect balance of stained glass and aquarium rocks, it's time to adhere them to the surface of the Plexiglas.

Note: Lay the molding into place, but don't attach it until you have covered the entire area up to the edge with either the stained glass or aquarium glass. This will give you some room when it comes to the cracks between the stained glass, spaces between the aquarium glass and space along the molding.

	Figure B
	Figure C

5. Start by applying the clear tub and tile adhesive (figure B) onto the Plexiglas. Use a clean scraper to smooth out the adhesive (figure C) to about a 1/4 inch thick over the surface for the glass rocks and 1/8 inch for the stained-glass pieces—working in an area no bigger than a 15 inch square at a time.

Tip: The less adhesive that is used, the quicker the dry time. However, there should still be enough to "grab" the rocks so they don't fall off when upright. There's a good amount of work time before the adhesive dries, but it can also take some time to hand-set the aquarium glass.We found that some glass pieces looked much nicer when each one was hand placed and some worked better when dropped randomly. The techniques vary a bit, so experiment and find the right technique for your composition and mood of the windows.

6. When you're ready to glue the trim in place, use the trim to gently push all the rocks into a straight line. Make sure to measure on both sides to ensure an even and level line.

7. Glue into place.

Figure D

8. Wait until all cloudiness disappears before moving on to the grouting step (figure D). Depending on the humidity and temperature, this could take up to a week.

9. For the stained glass, mix the grout as directed on the package.

Tip: When grouting aquarium rocks, we found it easier to add a bit more water to the mix, and then pour it over the rocks. We repeated this step, and then lifted the window slightly and "tapped" the grout into the small crevices. Let it stand for about a half hour, or until it sets properly.

10. Using a very large scrub brush, brush the residue off the rocks. This will also dig a little into the surface of the cracks and even out the grout. Let the project set until completely dry, and then brush again.

Safety Note: Wear a dust mask or respirator during this process.

Note: You can seal the grout, but it's not a requirement.

Figure E

11. Attach wheels to the bottom (figure E), and then metal eyehooks on top for the aircraft cable for installation.

Project Expense:

Molding, Stained Glass: Free
MDF, Plexiglas: $50
Glass Beads: $30
Materials: $20

Total: $100

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