How to: Cutting Glass for a Stained Glass Commission
In 2020 we relocated our studio to a new secret location, which gave us a bit of peace and quiet to get on with commissions and creative projects during the uncertain times of the pandemic.
It also gave us time to video the techniques used in making stained glass windows. In this post, we’re sharing a behind-the-scenes look at what goes into preparing and cutting glass for a stained glass panel—plus a few handy tips if you’re keen to learn more about the craft.
Planning the Design
Every piece starts with a pattern. For this commission, the design was created digitally and printed out in full scale. We’re currently focusing on the floral elements, and each piece must be carefully cut from yellow water glass—a textured glass that adds a beautiful ripple effect to the petals.
Choosing and Using the Right Tools
Glass cutting starts with choosing the right tools. For straight cuts, we always use a set square—freehand cutting might be tempting, but it rarely ends well when precision matters!
Our go-to cutter is a K-Star glass cutter with a steel carbide wheel, which offers more durability than standard steel cutters. It’s filled with cutting fluid (you can also use white spirit) to keep the wheel lubricated and ensure a smooth score across the glass.
Technique Matters
How you hold your cutter makes a big difference. We recommend the “beak” grip—holding it low and using your thumb for added pressure. This gives you control and reduces strain on your hands.
Before scoring, a small backwards nick on the edge of the glass helps break the surface tension. Then it’s all about smooth, steady pressure along the line—no need to press hard. Just keep it consistent.
Breaking the Glass Cleanly
Once scored, we use a W-shape hand position—fingers either side of the score, thumbs behind—to gently break the glass. For more complex curves or narrow pieces, grozing pliers come in handy. Their flat-and-curved jaw combo works like a lever to ease the glass apart without stress fractures.
Shaping and Refining
Even with the best cut, some pieces need a little tickle on the grinder to ensure a snug fit within the lead lines. A good grind makes for a smoother final assembly and helps the pieces sit flush without pushing each other out of alignment.
Got Questions? We’d Love to Hear Them!
If you’re curious about any part of the stained glass process—cutting, leading, soldering, or anything else—drop us a message. We’re always happy to share our knowledge and might even make a video to answer your questions.
Thanks for joining us behind the scenes!
– Chris and Justine