an
    
american
 craftsman

windowmaker

Patricia Vloeberghs scores and shapes fragile glass panes
into exquisite designs stained with her blood, sweat and tears


"Old-time craftsmanship wasn't always superior," says Vloeberghs. Of the half dozen repair jobs waiting in her studio's back room, she says, "A lot of this stuff wasn't built right.
THIRTY YEARS AGO, Patricia Vloeberghs was a professional dancer. It shows when she scores glass. Her weight on the ball of her left foot, the carbide-wheel glass cutter clutched in both hands, she swings her hips in a wide, precise arc to the right, keeping her arms straight. The hips pull the shoulders, which pull the arms, which pull the scoring tool in a neat, symmetrical curve--an eighth-scale replica of her hips' trajectory.

The wheel goes screeeeeeeeeeee. Glass embedded in Vloeberghs's forearms-tiny, nearly invisible splinters, the detritus of previous cut--glints under the fluorescent tubes overhead as she completes the score. By the time the etched line reaches the opposite side of the glass, she has shifted all of her 118 pounds over her right heel. She picks up the pane, positions a knuckle on each side of the score and with one quick motion snaps it, revealing an edge so precise it might have been inscribed by a compass.

"Yes!" she shouts. In her everyday working garb--including a vest festooned with Looney Tunes characters, a blouse embroidered with pink butterflies and three earrings in each of her ears--she does a quick two-step in celebration of the successful cut. Never mind that it's perhaps her millionth perfect glass-sundering. Never mind, because Vloeberghs loves her work. Crank up the verb: adores, treasures, cherishes, exalts, embraces, glorifies, idolizes. The alchemy of lead, glass and light imbues her with a religious fervor. Of her tenure in this cramped, hot Atlanta studio, she says "I've been in heaven for 18 years.

Constantly talking, constantly moving, a font of crackling energy, Vloeberghs, 51, is among the country's best leaded-glass craftsmen, designing and assembling ovals, trapezoids, rhomboids, cabochons and one-of-a-kind flowing forms into domes, transoms, skylights, sidelights, doors, cabinet fronts and stand-alone art pieces for hundreds of fine houses, mostly in the Southeast. You can say she makes stained glass--most people do--and she sometimes says it herself, but she prefers the term leaded glass because most of her work consists of clear glass, with only the occasional touch of color.

"I hate most stained glass," says Norman Askins, an Atlanta architect for whom Vloeberghs has created more than 200 pieces. "But Pat's windows go to another level."

Pat Vloeberghs

Pat Vloeberghs "Elegant, elegant, elegant," Vloeberghs says, waving a hand at the dozens of layout drawings taped to her studio's cinder-block walls. "I can do a bird of paradise, but most of what comes out of here is simple and clean. I can make something that works in any house: Jacobean, art nouveau, deco, Edwardian, Arts and Crafts, anything." She cites, in particular, the spare, precise geometry of the clear windows she made for the renovated Margaret Mitchell house in downtown Atlanta. Situated in the writer's alcove, they are exact reproductions of the windows Mitchell gazed through more than six decades ago as she wrote Gone With the Wind. "That was an ethereal job," says Vloeberghs. "I could feel her presence. I think she peeks through them even now."

On this sultry morning, Vloeberghs is assembling a medieval shield entwined with translucent ivy leaves--part of a 26-window job for the $21.5 million Carolyn Blount Theatre in Montgomery, Alabama. Dozens of 2-inch steel nails--the kind used for horseshoes--bristle out of the work, temporarily pinning down the lead channels that snake around the glass pieces and secure them. She uses the channels, known as came, the way a sketch artist uses charcoal. "The lines around the pieces bring them alive. I use 3/8, 1/4, 3/16, 1/8 inch, all different widths. The line expands and contracts, ebbs and flows."

Like all of her work, this one began with a double-decker sandwich of graph and carbon paper. Bearing down with a number-four pencil on the top sheet, she simultaneously makes three drawings: the cutout pattern, the layout pattern and the building pattern. Watching Vloeberghs draw is unsettling. Without hesitation, her bold strokes flow from top to bottom as if she were tracing an invisible stencil. "People who watch me go nuts. I have this drawing in my mind, and I just project it on the paper and follow it. I don't know how I do it either."

With shears, she divides the cutout pattern into templates, lays each on a piece of glass and traces around it with a marking pen. She etches that outline with her glass cutter; the tool, the size of a fat pencil, has an oiled carbide wheel that plows a tiny groove in the glass surface. She breaks straight scores with one quick, confident snap. Curves are tougher. To make a deep concave cut, she must break off a series of shallower concave scores, any one of which might split off crazily and wreck the piece. She never forgets that restoration glass, which mimics the swirls and bubbles of 19th-century handblown panes, costs her $50 a square foot." You've got serious motivation to make that cut work," she says.

TOP: Vioeberghs often talks to the glass as she scores it. "I say, 'Cooperate, please.' Sometimes it answers, 'No, I don't think so."' BOTTOM: Toxic lead residue collects on Vloeberghs's fingers as she presses a piece of came (a slender grooved lead rod) around a glass pane, so she washes her hands as many as 30 times a day. "Some people who do this for a living have lead in their blood, but my doctor says I'm perfectly clean. "

Glass is odd stuff. Its molecules are disordered like those in liquids but are so rigidly bound that it has most of the properties of a normal, crystallized solid. Recent, careful observation of medieval stained glass has debunked the old myth that glass slowly flows, thinning at the top and thickening at the base. But Vloeberghs's practical experience does point to a strange, internal molecular dance: "If you score a piece, you have to break it right away. If you wait overnight, it won't break on the score. Its structure moves."

After cutting, she arranges the glass pieces on the layout pattern. "I could just put them in a box, but the layout pattern helps you keep track of what goes where," she says. Then she assembles them on the building pattern. Quality leaded-glass work demands obsessive, surgical precision--without it, tiny measurement errors magnify until, as the work nears completion, the glass pieces can wander ¼ inch or more from the building lines. When craftsmen try to compensate by sneaking in off-sized pieces, the result is both asymmetrical and structurally weak. "Every bump that you don't smooth out creates a pressure point," she says. Under stress, such as wind or a paperboy's errant toss, "that's where it will blow out."

Pat Vloeberghs
When the Vloeberghs made this 2000-piece dome for the mansion of an Atlanta developer six years ago, she charged $6,000; today he she would charge $13,000. Although the dome looks like a skylight, the glass is actually covered by a box in the house's attic. Timer controlled fluorescent tubes mounted inside the box simulate sunrise, broad daylight and sunset. Contrarily, after Vloeberghs snaps out a single puzzle-piece of glass--and some of her works have more than 1,000 pieces--it's not unusual for her to traipse 10 times to the grozing machine to create the perfect fit. Similar to a woodworker's spindle sander, this gadget abrades glass edges with a 150-grit diamond-dust rotating head, removing about 1/32 inch at a time. Vloeberghs test-fits, then grozes, test-fits, grozes, test-fits, grozes-hour after hour, endlessly. "I'm a perfectionist," she says.

Building leaded glass seems a genteel art-the soft scritch of scoring the panes, the rhythmic tap-tap of the horseshoe-nail hammer--but is actually freighted with danger. There is nothing sharper than broken or cut glass; literally a molecule wide, the edge can pass through flesh like a sword through smoke. On December 6, 1996, Vloeberghs’s apprentice, Rebecca Owens, then 22, dropped a 30-by-7-inch freshly cut pane across her upturned left wrist. The glass severed an artery, two tendons and a nerve and chipped the bone. Vloeberghs threw Owens into her station wagon and roared to Piedmont Hospital in 10 minutes as the young woman's lap filled with blood. A person Owens's size-5 feet 10 inches and 118 pounds-normally has about 5 quarts of blood. Doctors estimated that, by the time she reached the hospital, she had lost nearly 3. Had they waited for an ambulance, Vloeberghs was told, Owens would have bled to death.

Pat Vloeberghs
"All I wanted to do was sleep. They kept shouting at me, 'Don't close your eyes!"’ says Owens, a shy counterpart to the extroverted Vloeberghs. Owens has recovered 95 percent mobility in the hand. Due to scarred muscle tissue, she still can't press her middle and ring fingers together when her palm is open.

"I sent a bouquet of balloons to her hospital room. One of them said, 'First prize for best cut!"' recalls Vloeberghs. She takes a deep drag on a cigarette--midway through the day's two packs--and grins wickedly. "Another said, 'Congratulations, you are now a stained-glass artist!' That shocked people but, hey, I've severed two tendons in my fingers. I took 30 stitches in my palm. It can bite you bad, but you can't let it scare you. You make a mistake, you go on. We don't do defeat around here."

Vloeberghs forged that attitude during her difficult childhood in Kalamazoo, Michigan. "I was a dyslexic, but I wasn't diagnosed until I was 21. I was considered stupid, but I just didn't see things. Even today, the letters turn and twist " she says. "I was also hyperactive. So while I couldn't do numbers and letters like the other kids, I was always looking for an outlet, some way to express myself.  I did ballet at 4, tap at 6, jazz dance into my teens." She earned the tuition for art school classes by working as a go-go dancer in Grand Rapids. "I did batik in Michigan, sculpture in California. I bounced in and out of everything in the art world."

Throughout, two memories percolated in her subconscious. One was her first recollection: staring, at age 2, at the glorious stained-glass windows at St. Luke's Episcopal Church in Kalamazoo. Vloeberghs was born with synesthesia, a rare perceptual condition that causes the senses to mix and mingle. For her, sunlight pouring through the windows literally made music. "Blue was a deep bass," she says. "With gold hues, the tones got higher. Greens were cool, soft, modulated tones. I just devoured those windows." The second memory was of the blissful days she spent as a child with her grandfather on the shores of Michigan's Gun Lake. "He began painting when he was in his 60s," she says. "He would wake me before sunrise and take me outside. We'd get down on our bellies and watch the sun coming up through the dewdrops on the grass. We would study the veins on leaves, how the moss climbed the trees." With his encouragement, she started painting in oils at 7; at 9, she sold landscapes at art shows. "He always told me, 'You can be anything if you work hard enough. Put one foot in front of the other and go."'

Pat Vloeberghs
TOP: Windows delivered to a buildingsite await installation. TOP CENTER: Vloeberghs applies 50-50 lead-tin solder evenly across joints. BOTTOM CENTER: She makes her own molds and pours decorative lead castings: wheat shafts, five-pointed stars oval pearl flowers, rosette stars, arrowheads, bellflowers and laurel leaves. BOTTOM: Soldered to the window the castings give the work another dimension," she says.
A Quality Test

Well-built leaded-glass windows can last half millennium. Bad ones can crack, bulge, sag, rot, leak or pop out chunks in two years. "You got to know what to look for," says Patricia Vloeberghs. "There is a lot of junk out there."

Inspect the window to see that all glass edges are smooth. "The little chip creates a weak point," says Vloeberghs. "If you press the glass, it could break a line radiating from that chip." If possible, shake the window. If pieces rattle, it probably wasn't cemented properly. As a final step with her own windows, Vloeberghs uses a stiff-bristled brush to force into the lead channels a body makes of glazing compound, boiled linseed oil, Japan dryer, paint thinner and lampblack. "It waterproofs and solidifies the windows," she says. "Some people use just glazing compound, by it's too stiff -- it doesn't allow for expansion, contraction and everyday vibration. Other people use nothing which is worse."

Inspect the channels. Vloeberghs advises avoiding zinc channels, which are made from a flat sheet of metal folded to make the characteristic H profile: "Water can travel through the folds and corrode it." Solid lead channels, she says, will last for centuries. To test a channel, scratch with a fingernail -- lead scoops out; zinc doesn't. Check to make sure channel joints are precisely soldered: "You don't want a tiny.or a huge clump of solder. Solder should neatly cover the joint."

Leaded glass weighs up to 5 pounds per square foot and needs support both vertically and horizontally. Vloeberghs's rule: Reinforcing bar should snake around a piece so that no area larger than 22 square inches is unsupported.

When installed in a wooden frame, the leaded glass window should have a 1/8-inch gap on the top and sides to allow for the wood's seasonal movement.

In her early 20s, Vloeberghs settled in Atlanta with Bob Cozine, a champion slot-car racer, and one day poked her head into an antiques store that included a stained-glass workroom. Every passion she had ever pursued intersected, fused and glowed in that dingy, cluttered shop: color, light, sculpture, movement, dancing, drawing, building. "I knew, immediately, that this was what I had been working toward. I was born for this. I had to get my hands on that glass." Though the owner was a "nasty little English gentleman" heaping on assignments and paying nothing, she stayed three years doing only repairs. "Taking so many things apart", she says, "you learn the best way to put new work together." Eventually, her dyslexia proved no hindrance. "On a tape measure, I learned to read spaces, not numbers. To me there's no such thing as 36 7/16 inches. I say, 'Cut that 36 and one quarter plus an Eighth plus a sixteenth.’ Drives my husband nuts, but it works."

In 1979, she borrowed $1,000 from her mother, bought tools and rented a bay in a former Atlanta dairy. "I worked that first year on a pair of sawhorses. I kept grubbing, grabbing I went to every antiques store in Atlanta, doing repairs on site." And she cultivated architects, teaching them that there were choices beyond the stained-glass unicorns, daisies and rainbows slapped together by cellar hobbyists. Eschewing pattern books, she drew her layouts from scratch and vowed to each customer that she would never repeat a design.

One day in 1988 a client strolled into the studio with a 14-year-old daughter in tow. The girl's eyes widened as she took in the iridescent glass, the spiderweb-came tracery, the dancing light. 'I want to do this," she declared. Vloeberghs, never one to dismiss ambition, wrote down all of the tasks the girl needed to accomplish before becoming an apprentice: attend college, major in art, study perspective, drawing, art history--a long list. "I forgot about it. Rebecca Owens
Two years ago. Vloeberghs's apprentice, Rebecca Owens, nearly bled to death as a result of a glass-shop accident, "Not once did I think about quitting," Owens says. "No matter what, I will always do this."
Seven years later this lady marches in with the list, all checked off, "says Vloeberghs, clapping Owens on the back They have been together four years. "She's a workaholic like me."

"She's making me into her clone," says Owens.

Their plan: Eventually Owens will take over the business Vloeberghs has so painstakingly constructed. Vloeberghs, hopes to teach college classes and finish a book she's writing on glass technique. But she'll never vacate the studio entirely. "I'll turn the heavy work over to Rebecca, but I see myself in here at 80 saying, 'Hey, baby girl, you didn't cut that right. Try again."'

Thinking about the future, Vloeberghs's gaze becomes distant--to her, growing old in this studio is an image to savor. Sometimes, she tries to imagine what might have happened had she never stumbled across that crotchety Brit's workroom.

What if she had never found this work?

Her brain, so often her adversary, now becomes merciful--it stutters and stalls. "I'm not sure what I would be doing," she says softly. "I can't even think about it. It saved me."

Pat Vloeberghs

By BRAD LEMLEY PHOTOGRAPHS BY NOAH L. GREENBERG

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Vloeberghs Stained Glass Studio, Inc.
2711 Piedmont Road
Atlanta, Georgia 30305

Phone # 404-261-3073

Copyright 1998-2010
by Pat Vloeberghs
ALL RIGHTS RESERVED