Part 1, White Knuckle Ride.
O.K. so it goes like this...
I've got six weeks to knock off an exact replica of a 12' x 8' 19th century stained glass master work by the F.X. Zettler Studio of Munich, Germany that depicts the baptism of Christ.
Normally this is an 10 week proposition but as usual the fates conspire against me and I am only now free of other studio obligations and can sink my teeth into this thing proper.
But I digress, first the background.
Beyer Studio is doing the stained glass windows at a new Church in Chester Co. PA named Mary Magdalene. Most of the windows going into the new building are adaptive reuse windows removed from St. Aloysius in South Philadelphia and from the the original St. Mary Magdalene. One of the windows they wanted from St. Aloysius, was the baptism of Christ unfortunately it was already spoken for.
We of course jumped a the opportunity to offer to make them one exactly like it. I'm going to attempt document the creation of this window and my inevitable decent into neurotic spasms in the process.
Allow me to introduce you to Mr. Zettler:

Beyer Studio (sadly) removed this window from a really beautiful Church in S. Philly two years ago, this job has been in the pipe line that long. It's funny how that pipeline more resembles a gun barrel as I get closer to deadline for this window.
Again with the digression.
Week One
Neil Cippon, computer wunderkind, photographed each section of the original window in an easel at the shop and then assembled the window in the computer.
We made some alterations to the composition to make the window so that it would conform to the frame dimensions of the Churches baptistry.
Neil then printed the window out at full size with our plotter and this is what I used to pattern out the window.

The printout.
Of course this all sounds very straight forward until you begin to factor in that Neil is being hounded by architects and frame makers for other jobs and no less than three other people in the studio are driving him nuts to get their projects printed (which all have the same deadline as mine). Also he is the only one who can operate the computer without invoking the blue screen of death. Neil juggles chain saws for fun.
Once I had my hot little hands on the full scale printouts I patterned the window sections. This consists of laying out card stock and brown paper under the printout with carbon paper between each layer. I then trace all the original lead lines of the window and end up with a glazing drawing and card stock glass patterns that precisely match out original. Pretty cool huh?

The layout.

Each piece numbered.
All the patterns get cut apart with a spiffy set of sears that has three blades and thus can consistently remove a thin strand of paper from between the patterns that allows compensation for the heart of the lead.

Cut apart.
By the time I've got this design reduced to a giant paper puzzle it's Thursday.
I start selecting the glass I want to use in this window realize immediately that I didn't order enough of a couple colors I need and tear apart the studio looking for alternatives.

Lamberts antique glass sheets used in the landscape.
Neil and Jason cut glass for me as I strip down full sheet of antique Lamberts (classy German mouth blown glass) as fast as I can. My boss Joe tell me he doesn't think I can make the deadline. I say I don't either, but being an artist I've gotten used to the concept of living a lost cause and I tell him I'm going for it anyway.

glass pile

Jason cutting
Fucking Paint! My boss urges this repeatedly to motivate me to stop selecting the window glass and move on to painting the line work (called tracing). The biggest problem with this directive is that there is almost not enough glass cut to effectively trace. To top it off Neil has know idea where the glass I stashed for this gig is located in the racks. I piss off my boss by selecting for another couple of hours before I cave and follow directions. I begin tracing the heads and hands, not what I had in mind to warm up with but that's what I got. My wife calls the shop and tell me my son Luke had a fall off a chair and cut his head and I need to get home. Joe is not happy. Luke is fine by the time I get home.
Week 2
Week two starts on Sunday with a painting marathon. Traced cherubs, John's head and an Angel in brocaded robes. Boss is no longer annoyed with me. Off to a good start.

Tracing on the light table.

Detail.
I fire the Cherub heads because someone had extra room in the kiln, one of them cracks up the middle.
So much for the good start.

Neil says if we're gonna get this done I'm gonna need more coffee.