4 Hearts

This is the completed restoration of the beveled window & its sash.

There were five broken bevels.  The zinc metal matrix which had supported it had oxidized to the point where you could not solder the joints back together.   It was time to re-zinc the window.

Before any work can begin a rubbing is taken from the existing window.  This is done with a charcoal block or a large graphite pencil.  Then you draw fine linework centered over the highlighted area of the rubbing.  This is the build line that defines where the new zinc will go.

After taking the window apart the glass is cleaned and new pieces are beveled to replace the broken ones.

Once all of the broken pieces of beveled glass have been re-beveled, the window can be reassembled.  Matching zinc inner and outer bars are used that are of the same die as found in the existing window and are termed “Colonial Inner Bars”.  This keeps the window historically correct.  The three wheel machine on the table is a caime roller bender that forms the zinc into curves.  A metal band saw cuts and miters the zinc to fit.  I find that the blue tape keeps everything from shifting and the zinc is kept in alignment. It makes soldering much quicker.  I constructed a sash out of cypress.