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Glass Door Knob Learning Guide

 
 

Materials Available on JubileeCreative.com                                                           Household / Miscellaneous Items

ü  Standard Paper Hole Punch
ü  Scissors / Ruler / Pencil
ü  Elmer’s Clear Glue
GS100 - Grinding/Edging Stone
ü  Paint Brush / Toothpicks
ü  Small Measuring Spoons
 
ü  Dish Soap and Water
 
Wash Mold with Glass Separator
 
1.     Apply 2 – 3 thin coats of mold wash to the mold. Make sure that all crevices and the deepest part of the cavity are covered with wash. We recommend Primo Primer Mold Wash. 
 
Make Fiber Paper Punched Holes
 
2.     Punch 5 disks from 1/8” fiber paper for each mold cavity with a standard paper hole punch found at most office supply stores.
 
Load Paper Dots on Post
 
3.     Locate the nichrome wire posts that came with your mold. If any of the wires are bent, straighten them as much as possible. Use the wire posts to pierce the fiber paper disks. Stack 5 fiber paper disks through the middle on each wire post. Slide the disks to one end of the wire post. Be careful not to distort the fiber disk shape.
Wrap Fire Paper around Dots
 
4.     Cut a 1⁄2” x 3⁄4” piece of Thin Fire paper for each cavity in the mold. Gently wrap the fire paper around the disks on the nichrome post making sure to not squeeze or distort the disks.  Use a small dot of clear Elmer’s glue to keep the fire paper tight around the disks.
Put Posts in Mold
 
5.     Place the exposed wire end of the nichrome wire post down into the center of the lower portion of the knob cavity in the mold. Adjust the wire and wrapped fiber paper disks to make sure that the wire and disks are centered and resting on the lower cavity of the mold. Also make sure that the disks and paper are at the top of the upright portion of the nichrome wire posts and no large portion of the post is sticking above the fiber paper disks.
Fill Lower Portion of Mold Cavity
 
6.     Begin to fill the lower portion of the mold cavity with fine glass frit.  This ensures a solid fuse of glass around the fiber paper disks. Fill the rest of the cavity with fine or medium sized frit and other fusing elements such as stringers, noodles, small dichroic scraps, etc. If a clear cap is desired, top with approximately one tablespoon of medium sized clear frit.
Fill Rest of Mold with Frit
7.     Use a paint brush or toothpick to tuck the frit away from the sides of the mold before fusing.  By creating a mound of glass in the center of the mold. This keeps the frit from sticking to the side of the mold which can leave sharp burrs. If any burrs exist after firing simply use a diamond coated grinding pad or grinding stone to smooth them.
 
Place Mold in Kiln
After Firing Knobs in Mold
8.     Place the mold up on kiln posts inside the kiln and fire to a full fuse using the below program.

Segment
Ramp
Target Temperature
Hold Time
1
300º F per hour
1360º F
20 minutes
2
300º F per hour
1465º F
10 minutes
3
9999º F per hour
960º
1 hour
4
100º F per hour
815º
5 minutes
Note: After firing let the kiln cool naturally back to room temperature.  Opening the kiln before it is room temperature can cause the fused glass to crack.
 
Knob Out of Mold
 
9.     Remove the fused knobs from the mold and remove the nichrome posts and fiber paper from the channel in the glass. Clean knobs in soapy water to remove all mold wash and fiber paper residue.
Fit Knob Hardware
 
10.  Fit knob hardware. Insert the threaded brass hardware part into the fused knob cavity to see if it fits. It should slide easily into the cavity. If the threaded brass part does not fit, it may be necessary to use a Dremel tool with a diamond coated drill bit to clear anything keeping the threaded brass insert from fitting.
Insert and Glue Knob Hardware
 
11.  Place a small amount of E6000 glue on the end of the threaded part and insert it into the cavity of the knob. Allow the glue to dry a minimum of 24 hours.  Use the screw to attach the knob to your cabinet door.
Clean Mold with Stiff Brush
12.  Cleaning your mold.  Casting molds perform best with a fresh coat of kiln wash after each use. For safety reasons always wear a dusk mask when cleaning molds. To clean your mold use a stiff bristle brush to scrape out the cavities and crevices of the mold.  It is important to remove as much old kiln wash as possible before reapplying the mold wash.  We recommend that molds never be cleaned in water.
 

Ideas: 

Mix Frit Colors!

Mix colored glass frit with clear to give your door knobs a dimensional look.

 

Add a glass decal!

After fusing and before removing the nichrome post, apply a decal to the top of the door knob, place each knob back in the mold and run a low fire decal firing program for low fire gold decals or a contour fusel firing program for high fire decals.   Adding decals can add a bit of elegance to your door knobs.

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