Lemon Door Panels - Brian's way!

I built these panels some years ago for my step son and his new wife. The have moved since and now I am confronted with the task of making them larger to fit a door in their new home!

I THINK that is easier tham making
them smaller and I am naturally
consoled by that fact!

I will do an article on that operation when I do it but for now I want to tell you
how I built them originally!

Again with a lemon theme there is a hanging lamp shade that needs to be converted into a table lamp! I do lead such an exciting life! You will have that to
browse too - later!

Because I never expected to be doing this web page lark back then there are no progressive pictures! So I will have to rely on words to try to explain the process!

First I fixed 4 wooden batons to my bench top to represent the glass area of the panel (allowing for 1/2in zinc surrounds).

Then I cut and foiled the amber border which I tack soldered in place. Next I cut a piece of glue chip to fit then placed it in the opening.

I made a plastic template and used it when I cut 10 lemons. That was a bit of a mistake - they could have been more varied in size. 50 leaves were done free hand! In the end I used 9 lemons but 60 leaves across the 2 panels!

Then I just laid out 5 lemons on the smooth side of the glue chip and some leaves and just shoved them about until I as happy with the look - drew around them with a felt marker and numbered them!

Because of the free form 'designing' there were very few cut lines to worry about - many combining to form a central 'stalk'!

Then I cut the gluechip to accept them - effectively an inlaying process. Foiling and soldering followed then fitting the zinc frame finished the job!

When I did the second panel I had the first on the bench along side so I could get a sense of the overall appearance. I was keen that the two should not be the same. I felt that symmetry is usually ok in a single panel but too formal in this instance in adjacent pieces.

I have used this method to make a number of panels and windows and I see no reason why it shouldn't be used for lamps too. Maybe I will do one soon and document it with some progressive pictures!