Winter Challange 2024 - Pam's Flour - Jim Donovan

[jerryrbeach]

Jim,

Just, "WOW!".  If I wasn't already amazed by your use of the laser to cut the brick paper I'd be looking for more adjectives to describe the insanity of cutting curved cover glass windows.  I struggle to cut glass for my storefront windows using a straight edge, and often end up by hiding the less than straight cuts I get after multiple efforts. I cannot imagine trying to cut glass for even a couple curved windows, much less a hundred.   

[Mark Dalrymple]

Looking really nice, Jim.

Do you have a plan to try to lesson the repeated patten of the bricks?  I know Troels Kirk did some amazing stuff with paints to his walls.  Also George Sellios with those 'Trains of Texas' walls.

Cheers, Mark.

[ACL1504]

Jim,

Fantastic build my friend. This is a great add for a laser cutter. However, I won't live long enough to learn how to use it. I'm sure the learning cure is another story.

Tom

[Jim Donovan]

Very impressive!  I've never tried real glass...

dave

Thanks Dave

I've had several comments on cutting glass, especially curved so I am adding a little more information on the post.

Jim

[Jim Donovan]

I've done a few cover glass windows.  I think it would be near impossible to cut the arch consistently. 

Jeff

Hi Jeff;

It is not the easiest thing in the world for sure but it can be done. It is one of those things that the slower you go the faster you will get done. I', posting a little more information on how I am doing this.

Jim

[Jim Donovan]

Jim,

Just, "WOW!".  If I wasn't already amazed by your use of the laser to cut the brick paper I'd be looking for more adjectives to describe the insanity of cutting curved cover glass windows.  I struggle to cut glass for my storefront windows using a straight edge, and often end up by hiding the less than straight cuts I get after multiple efforts. I cannot imagine trying to cut glass for even a couple curved windows, much less a hundred.   

Thanks Jerry;

Like I told Jeff, not the easiest thing I have ever tried for sure but doable. I am going to post a little more on it so might give you some ideas.

Jim

[Jim Donovan]

Looking really nice, Jim.

Do you have a plan to try to lesson the repeated patten of the bricks?  I know Troels Kirk did some amazing stuff with paints to his walls.  Also George Sellios with those 'Trains of Texas' walls.

Cheers, Mark.

Hi Mark;

Yes I will be using dry brushing, and pigments once I have have placed all the detail stuff on the walls and before the glass goes in place. Matt clear varnish will tone everything I put on the walls down. If I do it right (no promises) the repeat should be gone. We will see.

Jim

[Jim Donovan]

Jim,

Fantastic build my friend. This is a great add for a laser cutter. However, I won't live long enough to learn how to use it. I'm sure the learning cure is another story.

Tom

Frankly Tom if I modeled as good as you do I don't think I would worry about lasers or 3D printers either. Thanks for tagging along.

Jim

[Jim Donovan]

I've received some comments on the use of real glass and the difficulty of using it so I would like to explain how I do it a little more in-depth. First, like most things, the more you do it the better your results. I like the look of glass so I am willing to put up with the failure rate and frustration of cutting a shape only to have it break on the last cut. Second I have found only one tool that works consistently in cutting slide glass, the General Tool Scribe #86. I'm not sure if it was Bob Parrish or Bob Hamm who told me about this tool first but nothing else I have tried has worked, period.

There is a much better glass available for windows, offered by Clover House, it is an amazing .05mm thick were the slide glass is .13-.17mm thick. I can cut this material with a very high rate of success and I have seen Bob Hamm cut complete circles out of it. Unfortunately they are temporarily closed due to illness. Hopefully they will reopen soon. So for now I am stuck with slide glass but the good part is it is much less in cost since I only get it right 35-50% of the time.

To cut these windows I two step the process. First I make a single score across the slide in the width I want. I don't worry about the height at this point, just a nice straight cut. I use a little tape jig I make on the work mat for this process and a clear plastic ruler to see that the slide is in correct position to score the glass line. After scoring I place the glass on a 2 x 4 metal block I normally use for weight with the score line on the edge of the block. I gently press down and if I scored it right it simply snaps off.  After a little practice this usually goes fine. Then I place the die I had the laser cutter cut out of 2 mil styrene in the dimensions of the window (actually .1 mm smaller in all dimensions to account for the scribe adding width. When stacked correctly I gently score the curve of the die in one direction, towards me,  until the corner snaps off. If done right I have a curved window. Sometimes the curve might not be perfect but if only a little jagged the window frame will cover it and I still use it. Since the window frame is fairly soft resin I slide the glass in place with about 1-1.5 mm sticking out the bottom. Then I gently tap the bottom against the work mat till the glass is completely seated, being glass it works its way into the resin somewhat. If any glass is still showing on the bottom I use the scribe and cut it off. Finally a dab of canopy glue across the bottom of the window which will dry and hold everything in place. So here is a better picture of the  make do jig (the white die is in the correct place when used) and the final result after cutting.  Most of my failures are on the curved part so I cut up 10-20 'straight blanks') first then work on the curve.

Hope that is a better explanation.

[GPdemayo]

Tedious work Jim, but the results are amazing.....

[Jim Donovan]

One thing I forgot until yesterday. In order to get the cuts as constantly smooth as possible it is important to cut on a hard service, not the mat as I showed. It has been a while since I used glass in a building and had forgotten this most important fact. I have a sheet of tempered glass I use for cutting brittle items, once I switched over to it my success rate jumped to 75%. Not sure why I forgot except old age. The surface you use to cut is all important.

[ACL1504]

Jim,

Cutting the glass on a hard surface does make sense. Great job  anyway.

Tom

[Jerry]

Glass cutting 101 etc.!  Thanks for how you do this.

And the build is coming along nicely.

Jerry