A few times a year we are asked to restore concave/convex leaded diamond pattern windows. Many people think that these windows were originally flat and that they sagged due to age, and people poking on them. While this may be true in many cases there were a significant number of windows that were made concave/convex intentionally. We don't see too many being made today simply because it is a time consuming process, and most manufacturers either do not know how to build them, or just don't want to put in the time.
In fact the first time I encountered such a window I though it had sagged from age, but the home owner informe3d me that he was a child when his father had them commissioned and that they were intentionally made that way when the house was built. It was from this experience that I learned how the windows were constructed, and what we had to do to restore, or duplicate them.
With this particular project there were other leaded diamond pattern windows that had been releaded, but flat rather than concave/convex. This project involved eight casement windows approximately two feet by five feet. Four were in steel sash, and four wooden sash. We removed all the sash and boarded up the window frames with plywood. This was easier, and cleaner than taking the windows out of the sash on site. Of course it was much safer also as we could remove the windows in our studio with no risk to them falling, or coming apart in the process.
The windows were in such deteriorated condition that we didn't have to soak them to loosen the putty. When we removed them from the sash they for the most part came apart in our hands. Of course we numbered the pieces first before removing them. Then we cleaned them and began the process of rebuilding them. The deflection was about 1" on each side, so we used 1" Styrofoam cut in 1 1/2" square to support each rise. The 3/8" H flat lead easily bends up and down, and the intersecting sections are cut to slip into the opposite channel. Once the window is leaded up, we solder the joints normally and glaze up both sides.
The reinforcing bars have to be placed horizontally rather than on the diagonal as we do with flat diamond windows. Of course this means that the bars are visible as they cut half way through the diamond, but there is no alternative.
As you can see the final result is dazzling. The reflection off the glass resembles a diamond, and really stands out, especially from a flat diamond pattern.
Adammsgallery.com Adamm's Stained Glass 1426 4th St. Santa Monica, CA 90401