bottle cutting: an art project
Author: 
Recipe type: miscellaneous
 
Ingredients
  • Lots of clean empty cylindrical glass bottles. I used beer, water, and wine bottles. Paper and plastic labels should also be completely removed.
  • Bottle cutter - I used the Kinkajou. Watch the YouTube videos on use before starting or read the owner's manual.
  • A large pot of hot water and a large pot of ice water (Each should have a separate large cup with which to dip and obtain water as needed.)
  • Gloves (gardening or rubber -- when shocking the glass with hot and cold water)
  • Safety glasses
  • Plastic grocery bags
  • Uninterrupted time (no young children around)
  • 80 to 600 grit waterproof sandpaper pages (a wet diamond wheel sander is better and faster, if you have it)
  • Optional supplies, only if decorating the glassware: Glass etching cream
  • Sticky vinyl or contact paper (painters' tape also works depending on your choice of design)
  • Hand-drawn designs or clip art (and carbon paper to transfer, optional)
  • Rubber gloves
  • Paintbrushes
  • X-Acto knife, to cut out designs
  • Cutting surface (like old cardboard)
Instructions
  1. Once your bottles are clean and free of labels, set up the Kinkajou bottle cutter where you want to cut a bottle. Please see the YouTube videos or the owner's manual for details. Score the line and remove the Kinkajou.
  2. Line your sink with grocery bags. When you separate the glass, there'll be sharp edges and you want the unwanted bits to fall into a bag, not down the drain.
  3. Position the separation rings around the scored line. Pour hot water over this line to heat the glass. Next, shock the glass with cold water over the same scored line. You may hear a crack before there is any separation. It may take two or three rounds of hot and cold before the glass completely separates. The thicker the glass, the more cycles needed also. After separation, carefully remove the separation rings and apply to the next scored bottle. Complete these same steps for all of your bottles.
  4. SANDING: The sharp edge needs to be addressed on each glass. Use your safety glasses and work in the sink. There will be very small pieces of sandpaper grit and glass flakes.
  5. Starting with the 80 grit sandpaper and the glass under running water (to prevent glass dust to aerosolize), sand the outside edge, top edge, and inside edge on each cut bottle until each is more smooth. The sanded edges will have a frosted appearance. To make them more shiny, use next finer grit sandpaper and work your way down to more fine grit until you achieve a more smooth and safe edge. Keep the glass and sandpaper wet for all of the sanding. Alternatively, you can set up a deep bowl of water in the sink, partially submerge your bottle, and sand. After you have sanded all of your cut bottles, give them a good wash in the dishwasher or by hand. (UPDATE: See the post body for more information on using a Dremel tool for grinding and sanding.)
  6. ETCHING: Read the instructions on the bottle very carefully, as different brands have different recommendations on how long to leave the etching paste on the glass. Mine took about 15 minutes with a thick, odorless paste.
  7. Prepare your workspace. I recommend newspaper.
  8. Draw your design on the vinyl sticker paper. If doing a mirror image or a complicated design that is already drawn on another piece of paper, use carbon paper** to transfer design. Make sure you get the correct orientation. I drew my designs on the backside of the vinyl sticker paper so I reversed my drawings when transferring, then had the final design in the correct orientation.
  9. When using the X-Acto knife to cut, use small deliberate movements for detailed designs. Take your time. It will be worth it.
  10. Retrieve your glassware and clean outside surface well with rubbing alcohol. Allow to dry and apply your design stickers. There may be some wrinkles given the shape of the glassware and the detail of the design. That's okay: make sure you press them firmly down to prevent leakage of etching cream, thus disrupting your design.
  11. Apply the etching cream in blobs and brush well into all corners of the design. Make sure to stay on design surface and the vinyl. Anything the etching cream touches on the glass, will be frosted. Follow the instructions on the etching cream bottle for length of time needed to etch. Mine took 15 minutes.
  12. Rinse well with cool water, blotting and wiping residual etching cream away. Peel off vinyl sticker to reveal your design. When the glass is wet, it may be hard to see the etched design. If you're careful with the final design sticker when removing, you may be able to use it again.
  13. Give all of the final edged glassware a good run in the dishwasher before using or gifting. You can also tweak any more rim sanding if needed.
Notes
* I used the Martha Stewart glass etching cream for this project. The Armour brand was not available. Here is a basic side to side a comparison of the two brands. The MS brand was thick and pasty, no chance of it running down the sides of a glass into areas you do not want to frost. Some sources I read stated the Armour brand was a bit runny. The MS brand also took 15 minutes to fully etch, while the Armour brand states only a minute or so is needed.

** Is carbon paper even made anymore? I remember seeing this in offices when a child. It seems so antiquated now but so useful!
Recipe by story of a kitchen at https://www.storyofakitchen.com/miscellaneous-recipes/bottle-cutting-an-art-project/