Occasionally, we get unusual requests from customers at work about cutting or salvaging glass items from their homes and vehicles. One such request lately was for a customer who had borrowed a lamp from somebody, but had managed to break the cylindrical glass lampshades that slotted onto the lamp. Without seeing them, I told him to bring them in and at least I could take a look.
When they arrived, they were actually really small in size, approximately 30mm in diameter, and a heat formed glass cylinder with a moulded inner base tube that slotted onto a mount. This one was going to be tricky. It was certainly going to be too small for all but one of the bottle cutters I have, but I decided to give it a go with the G2 bottle cutter.
The G2 cutter is the most flexible cutter I have in terms of the sheer range of size it can cope with. I set it up, and felt confident it would rotate and give a clean, even cut on the shades. It did work in terms of size, but I could tell the score wasn’t too successful just by the feel of it. This is most likely for a combinations of two things. Firstly, the outer surface of the glass shades were sandblasted, which makes it a textured surface. Usually this needs a deeper and harder cut. Secondly, as the glass is a single formed piece with an internal cylinder, I’m guessing that the shades become slightly heat strengthened by the forming process, making it a tougher glass to cut, though not unbreakable clearly. The usual hot and cold method didn’t achieve anything at all in terms of getting the score to run. Time for plan B.
There was no other alternative to tap, run of snap it, so I tried an electric water-cooled tile cutter. As the glass was quite thin (<3mm), the tile cuter was way too brutal to cut these shades. All it achieved was giving me a good soaking. Time for Plan C.
The last remaining chance was to turn to my glass grinder that I use for stained glass making. This would be tricky and time consuming to get the very jagged edges down to being as close to a flat cylinder edge as original, but I gave it a go.
The glass ground well, and using the grid lines on the grinder top, I got the three cylinders down to as flat an edge as I visibly could, which is not easy when you consider it’s a cylinder and you are using a round rotating grinder head. They were so erratically broken, I cut them to just below their lowest breaks, leaving three distinctly different height cylinders. This was as good as I could do, without spending all night grinding. I figured it would look good as the lamp stalks were three different heights anyway, and I could place them to suit the best look. I finished the tops of with the hand diamond pads, to give them as good an flat and arrissed edge as I possible could. The internal edges were too small to do anything with, but I was satisfied they were as safe as I could get them with the grinder.
All in all, I’m quite satisfied in how it went, as the job was really just a ‘make best or bin’ gamble with what had become a damaged and unsafe lamp. It looks pretty good in the end, and was a fun little challenge to do. I don’t mind tackling something like this, as you’ve nothing to loose, and it’s good experience with bottle cutting skills on objects other than bottles. A worthwhile and interesting task.