• Always, wear safety goggles when using glass-crafting tools. Everyday eyeglasses have only impact resistant lenses.
• Always wear a dust mask when cutting wood.
• To ensure top performance, always use water when cutting glass and oil when cutting metal.
• Always adjust the blade guide arm to ¼” above the material.
• If the you choose to use copper came with this project and would like to clean it up a bit, wipe it down with vinegar and gently scrub it with table salt to restore its brilliance.
• Precision 2000 or Precision 2000 Deluxe Band Saw
• Studio Pro Metal Blade
• 3 Green scrap glass in various sizes or green recycled bottles
• 1 Plank repurposed wood – we used deck wood scraps
• 1 chip board 12x13 or any other recycled wood
• 60” scrap dual channel copper or lead came
• 60/40 solder
• Flux and flux Brush, Copper or Black Patina
• Glass Adhesive – E6000
• Studio Pro Soldering Iron, Heat Resistant work surface
• Acrylic Paint – we used Apple Barrel – Tiger Lily, Red Apple, Country Grey, Spring Green and Americana Citron Green
• Paint Brush, Black and Silver Sharpie
• Heat proof gloves, Machine Oil, Ruler
• Wheeled glass nippers
Read and carefully follow the instructions contained within the Precision 2000 operations manual.
1. Paint the lower portion of a 12 x 13 piece of chipboard with a blend of green and grey acrylic. Paint the upper portion with a blend of smoky grey, orange and red for an amber effect. Use your brush to blend and scrub the paint into the surface. Allow to dry.
2. Set- up the Precision 2000 for wet cutting with a diamond blade. Make sure the water reservoir is full and the spray nozzle is properly angled. When ready to cut, turn the water supply on first and then the band saw.
3. On pieces of green scrap glass or on the surface of a recycled green bottle, draw a series of large and small swirl patterns (see sample swirl below) using a Sharpie® marker, cut 12-13 varying sized swirls to create the tree foliage. Use the drop-out from the original cut swirl as a smaller swirl, so you only need to make 5-6 cuts!
4. Begin cutting out your pattern staying on the outside of the pattern line. Push the glass into the blade slowly, with light pressure – the blade should make the cut. Do not push material into blade but gently guide it.
5. Following the directions in the Operation Manual, set the saw up for dry cutting and install the metal blade.
CAUTION: Wood and Metal Blades have teeth and will cut fingers, so be careful when cutting.
6. While band saw is off, use machining oil or metal cutting oil to lubricate the blade. Apply oil directly to the entire blade.
7. Slide the edge of the chipboard into the channel of the came and mark the location of the corners 8. Use the miter gauge and adjust to form a 45 degree angle. Wearing heat proof gloves slowly guide the came into the blade on the angle. Turn off the saw and add more oil as needed.
9. Repeat steps 7-8 to cut all remaining corners. Slide the sections of came onto the chipboard.
10. Clean away any oil residue left on the saw.
11. Following the directions in your manual, install the wood blade.
13. Measure and mark about twenty 1/8” – 3/16” sections. The length of each section will be determined by the depth of the repurposed wood.
14. Wearing a dust mask, begin to cut the wood where indicted, using gentle pressure, push the wood slowly into the blade – let the blade do the cutting!
15. Once the sections have been cut, lay them on your work surface and place the tree trunk pattern on top of the wood. Use a pencil and trace the outline of the tree trunk onto the wood. Not all wood sections will be used for the trunk, some will be used for the frame.
16. Cut out trunk where indicated.
17. Place the chipboard on a heat resistant surface, slide copper came onto each side of the board. Flux a corner and about 2 ½ inches down the side of the copper came.
18. Run a solder line over the seam and guide the solder to the other fluxed areas to create distressed look.
19. Repeat steps 17-18 on the remaining corners, varying the amount of flux and solder used to achieve a varied look.
20. When cool, apply a complimentary patina color to the solder (we used a copper patina).
21. To create the outer frame of the project, set the miter gauge to a 45 angle. Stack 4 pieces of the precut wood pieces and cut a 45 degree angle down the middle of the wood. Insert each of the angle wood into the 22. Continue to insert the precut wood pieces into the came channel. Cutting some of the pieces to fit snuggly around the frame.
23. Clean all of the glass swirls, removing any and all marker residue on the glass.
24. If you have scraps that are too small to cut with the band saw, nip them using a wheel glass nipper to form arcs.
25. Arrange the wood trunk and glass swirls on the chipboard to form a tree, using image for placement.
26. When you have achieved your desired look, glue pieces in place with E 6000.