Repairing a panel

The original panel

This panel contains a few broken pieces, but its main problem is that it has lost most of its strength, and is at risk of further collapse and greater damage.

The cartoon

The process starts with the creation of the cartoon which in this case is created using the same technique as brass rubbing. The panel is carefully pushed back into shape (as best as possible), paper is placed over it and secured in position, then a rubbing is taken using a crayon. This provides the location of all the leads and glass pieces.

Deconstruction

Once the cartoon is prepared, the panel can be taken apart. This must be done with care to avoid breaking any of the glass sections.

Pre-cleaning

All the lead has been removed and the broken pieces discarded. The remaining pieces are very dirty and must be carefully cleaned prior to reconstruction.

Post-cleaning

All the old cement and grime have been cleaned away, and new pieces cut to replace the broken sections using the closest available matching glass.

Leading up

The panel is now reconstructed using the cartoon to determine the positioning of each glass section and placement of the leads. It's a little like doing a jigsaw puzzle, with the advantage that you know where all the pieces go.

Ready for sealing

Once the panel is totally reconstructed all the joints between the leads must be soldered on both sides of the panel. At this stage the leads and soldered joints are still very shiny.

The finished panel

After soldering, leaded light cement (a special kind of putty) is forced between the lead and the glass in order to seal the panel against the weather and also to provide strength. Once set it allows the panel to expand & contract without cracking the cement. When the cement is set, the panel has patina applied to 'age' the leads, and is finally finished with black grate polish to shine & protect the leads.

It's now ready for another 100+ years of service.