Stained Glass Solder Bead Width Calculator
Calculate solder bead width for copper foil and lead came stained glass joints.
Get bead dimensions and total solder weight needed for any panel size.
Stained Glass Solder Bead
The solder bead is the rounded ridge of solder along a glass joint. Width and height determine appearance, strength, and solder consumption.
Standard bead widths by foil/came:
| Method | Foil/Came Width | Bead Width |
|---|---|---|
| Tiffany copper foil 5/32" (4mm) | 5/32 in | 1/8-3/16 in (3-5 mm) |
| Tiffany copper foil 7/32" (5.5mm) | 7/32 in | 3/16-1/4 in (5-6 mm) |
| Tiffany copper foil 1/4" (6mm) | 1/4 in | 1/4-5/16 in (6-8 mm) |
| Lead came U-channel | varies | flush with came face |
| Lead came H-channel | varies | flush, both sides |
| Zinc came | varies | thin bead at junction |
Bead height (cross-section):
- Flat bead: 0.5-1.0 mm — minimal solder, looks rough
- Standard bead: 1.5-2.5 mm — round, classic look
- High bead: 3-4 mm — heavy solder, max strength
- Pearl bead: 4-6 mm — maximal, for art pieces
Solder consumption math: Solder volume per linear foot ≈ Bead width (mm) × Bead height (mm) × 305 (mm/ft)
Where 305 mm = 12 inches.
Solder density:
- 60/40 (Sn60/Pb40): 8.5 g/cm³
- 50/50: 9.0 g/cm³
- Lead-free (Sn96.5/Ag3/Cu0.5): 7.4 g/cm³
- Sn60/Pb40 silver: 8.7 g/cm³
Linear feet of solder line in a typical panel:
A 12×12" panel with:
- 9 inner pieces (3×3 grid): adds ~36 inches of inner soldering
- Border (4 sides × 12"): 48 inches
- Total: ~84 inches = 7 feet of solder line
For both sides: 14 feet of solder bead.
Solder needed per 14 feet at 5×2 mm bead, 60/40 alloy:
- Volume: 5 × 2 × 305 × 14 = 42,700 mm³ = 42.7 cm³
- Weight: 42.7 × 8.5 = 363 g (12.8 oz) of 60/40 solder
Soldering tips for clean beads:
- Tin first: flow a thin layer of solder onto bare copper before bead
- Iron temp: 700-750°F for 60/40, 800-850°F for lead-free
- Move steadily: too slow = lumpy, too fast = thin/cold
- Iron tip choice: chisel tip 3/8 in works for most foil work
- Flux liberally: apply paste flux every 6-12 inches of run
Common bead defects:
- Lumpy: iron too cool, or moving too slowly
- Thin/voids: iron too hot, or moving too fast
- Ripples: dripping solder, iron tip dirty
- Spike points: flux dried, missed re-application
- Discolored bead: wrong solder, or oxidation from heat too long
Lead-free vs leaded:
- 60/40: lower melting (370°F), smoother bead, easier
- Lead-free: 410°F+ melting, brittle if overheated, harder to bead well
- Lead poisoning risk minimal in stained glass (vs jewelry/electronics)
- Good ventilation and washing hands prevents lead exposure
Solder for specific applications:
- Standard: 60/40 leaded
- Lead-came joints: 50/50 (matches came)
- Outdoor / food contact: lead-free Sn96.5
- Antique restoration: 60/40 with silver (matches old solder)
Cost estimates (US, 2026):
- 60/40 1lb spool: $25-40
- Lead-free 1lb spool: $40-60
- Most panels: 6-16 oz of solder
Tip — pre-weigh before starting: For consistent estimating, weigh your solder spool before and after a panel. Track linear feet too. After 3-4 panels, you’ll have a reliable per-foot consumption rate for your bead style.