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We did this project as part of the Colorized Atkinson Plates project back in about 1987 or so. We shipped it off to the Cleveland, Ohio Letterheads meet since we were too busy to get out of the shop. A lot of people wondered how we did the dimples in the border. About all we told them was it was done with BBs. Some people thought we shot BBs at the glass!
Actually, we used Anchor Sandblast Stencil for the masking needed for the etching and also for the frosting necessary for the glue chipping. We peeled the little slender panels in the borders and hand painted a few asphaltum ornaments in the clear, exposed glass. We then layed the glass flat and poured enough BBs in each slender panel to fill it completely with one layer. They didn't roll off because of the thickness of the Anchor stencil. At that point, we poured Hydroflouric acid into all the slender border openings, being careful not to get acid in other exposed areas, although that wouldn't have mattered too much knowing it would be frosted soon after the acid step. After about 30-45 minutes, we carefully rinsed the acid off and dumped the BBs into the trash. The asphaltum protected the ornaments and the little BBs slowed the etching enough to create the little divots.
We had to protect the acid etched areas when we did the frosting for the chipping, but that was easy.
If you ever try this process, use plenty of precautions as advised with the acid Material Data Safety Sheets. Do a few tests, too. While we had good success with Anchor Sandblast Stencil, I have heard others say the acid ate into the glue of some stencils. Also, we learned we had to be very accurate in the corners of the hand cut stencils. If we "overcut" the corners, acid would seep into the cuts and you could see the results from the front. Also, make certain to burnish all edges down firmly to keep acid out of places you down need etched.
It is an interesting process. I always wondered about using little washers with the serrated edges instead of BBs.
Mike Jackson
Ron Percell
Thats a great effect Mike, I really love seeing layers in a piece. It looks as if the BBs really fit well, and kept a uniform pattern too.
Denver Chapter of the Letterheads