How does the custom panel process work?
There are three phases:
- The Design phase where your involvement defines the style, color and any special needs.
- The Construction phase where the panel is built based on the approved design.
- The Packing and Shipping phase
The Design Phase:
- Your input is obtained as it relates to desired size, style, color and specific needs like privacy.
- Using scaled sketches, sent as scanned images, I obtain your feedback.
- Usually 3 to 4 passes firm up your design needs.
- Once a design is firm I offer a fixed price quote good for 30 days.
- For special complex projects I may request a design fee that can be used as a credit towards a purchase.
The Construction Phase, general comments:
- To start construction a deposit is requested, usually 50%.
- I book work based on deposits received. At the time of a deposit I give an estimated ship date based on my workload.
- Once started, construction usually covers a period of 5 to 8 days.
- I send digital photos as construction proceeds.
- When your panel is finished I send final photos. The balance is requested at shipping, usually a day or two after the final photos are sent.
- I sign all my custom panels with my initials and the month and year made, GAM mm/yy, so that when I am famous you can prove you have an original.
The Construction Phase, detail of the steps involved:
- Generate a full-scale drawing used for construction and to confirm glass segment size.
- Cutting the perimeter zinc came which establishes the panel's size.
- If the central element is a complex layout, like the Celtic Bevel Knots, I fabricate this section as a single unit to be
integrated into the panel. (Only some panels need this step.)
- Glass segment cutting and grinding and the cutting and shaping of the lead came that surrounds these elements.
- Solder the connections of the lead and zinc came.
- Cementing the panel.
- After 2 or 3 days, when the cement is dry, the panel is cleaned and then polished with a wax.
The Packing and Shipping Phase:
- Inner Shipping Box: This is a sleeve box lined with foam wrap or bubble wrap with the panel inside. The box is strapped to a
backing board for extra longitudinal strength.
- Outer Shipping Box: The outer box should surround the inner box with at least 4" of shipping peanuts in each direction.
- Shipping Limitations: For some design sizes a component design is required to meet safe shipping dimensions.
Usually a single unit over 4 to 5 square feet would need to be made in sections.
To see this information in PDF format use the following link --
How does the custom panel process work? It assumes you have the Adobe Reader available.
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