|I'd driven past this window many times over the past 30 years and always
thought, "that would be one heck of a window to repair", it being curved
and consisting of all beveled pieces. Well, the phone rang one day and
the window needed repair - again. It turns out this 100 plus year-old
window had been repaired before, probably several times, and not very
well. Seven of the beveled pieces had been replaced with regular,
non-beveled window glass. The zinc came was bent in places and silicon
had been used to fill gaps. Besides having a broken pane, the window
was also falling out of its wood frame due to the bottom section of the
frame coming loose.
|After numbering the glass pieces and photographing the window, I disassembled it.
I made cardboard templates for 8 beveled pieces to be re-created then mailed them to a beveling company in
southern California. The original zinc came was too far gone to reuse so I also ordered new came.
|My original plan was to rebuild the window flat
on my work table then set it back into its curved
frame. After repairing the wood frame, I cut a
piece of 1/8" thick white board to the proper
size. This was going to be my template to build
on. When I set it in the frame to check its fit I
thought, "maybe I can build it right in the frame
then slide out the white board". It was worth a
try. I had rebuilt several windows in their frames
|From previous experience I've
learned that rebuilt windows don't
always exactly come out to their
original size so I did a "pre-fit" test
using the old window pieces and
the new came I ordered. Sure
enough, I had to make minor
changes in the perimeter came
pieces for a good fit.
|Rebuilding in frame supported by
|After soldering all the outside came
joints, I carefully slid the white
board out. The window was now
self supported. I replaced the wood
strips that hold the glass into its
wood frame, then flipped the entire
unit over and soldered the came
joints on the inside.
|I masked off the wood
around the window then
puttied and applied
carbonate) to the
window to help the putty
|After vacumming off the
remaining whiting, I dulled
down the new, shiny came with
a patina to make it match the
other windows whose came
had naturally darkened with
After a thorough cleaning, the
window looks as good as new.
|The repaired window back in place.
|Curved Window Repair
(click on images for larger views)