How to Repair a Broken Copper Foil Panel

​How to Repair a Broken Copper Foil Panel

​It's truly unfortunate ​that ​accidents happen and beautiful​ copper foil window panels get damaged. But it's a reality when dealing with glass that sometimes​ they do get broken.

​Repairing broken pieces takes time and patience, but even if you're still fairly new to making stained glass, you can still benefit from learning how it's done. Sooner or later you'll have a piece that needs repairing.

Over the years, I've had a few projects that needed repairing before they were even completed! It was usually due to a heat crack that turned up during soldering.​ Maybe you've ​had pieces in need of repair from accidental breakage too?

Well, if you do have some, ​​now you can see the process to repair them.

​I've created a video that walks you through how a repair is done, complete from removing the broken piece of glass all the way through soldering the new one in place. ​This ​video shows a broken piece of glass in the middle of a copper foil stained glass panel and all of the steps needed to repair it.​

This post contains affiliate links, meaning, I recommend products and services I’ve used or know well and may receive a commission if you purchase them using my link (at no additional cost to you.)

​Want to know what tools and supplies I used in the video? ​Here's a h​andy list.

​Give ​it a try!

​Every repair brings​ unique challenge​s and you'll learn a lot from doing them.

I suggest starting with a simpler repair like the one shown in the video. The panel didn't bend or break in multiple spots which means that the integrity of the structure was still intact.  This means that you can focus completely on the one piece without fear of the panel being unstable or easily fractured elsewhere simply by turning the piece about or tapping on the broken section.

If you love this design, the stained glass dragon pattern can be found in the store using this link: Dragon Pattern.

I'd love to hear from you! Leave reply in the comments and let me know what your favourite repair tips are.

Leave a Reply 8 comments

BJ - May 24, 2018 Reply

Thanks for this great video. Making a foil repair now seems more achievable. However, I do have one question. When you heated the solder and removed the foil from the opening, did it leave the foil intact on the surrounding edges? You didn’t mention having to refoil the surrounding glass pieces before you put in the newly cut replacement piece.