To cut glass lenses (for example, to trim the sides off a circular lens to get a square), you'll need a diamond saw.

If you don't have one:

• Check the yellow pages for a rock & gem shop. See if they will allow you to use their diamond saw. BribeEmployee if necessary or to show thanks.

• If you have a DremelTool (or another small drill), you can purchase little diamond cutting disks (mini diamond saws) in a DremelTool? size. You should get a saw and one or more grinders. The saw for rough cut, the grinder for cleaning up. These items should be available at a well-stocked hardware store, or at aforementioned Rock & Gem shops. Mine cost under 10$ CDN. They wear out, so you may need a couple.

• You will also need eye protection, an apron, a mouth/nose cover (like painters use) and possibly gloves (thin rubber or latex).

• Finally, you need a way to deliver a thin and steady stream of WATER (just a little trickle) to your cutting area.

Assuming you have the necessary tools, here is what's going to happen.

The saw and grinder(s) won't look like much - they aren't even very rough - but they WILL cut/grind down the glass nicely.

Cutting glass REQUIRES a constant water trickle! This is to:

• Provide lubrication
• Wash away/contain the fine glass powder that will be created
• Provide COOLING (very important)

How to Cut A Lens (or any other piece of glass)

1. Set up your dremel (with appropriate bits) and your water source.

2. Put on all your protective clothing (white water will splash on you, and when it dries it will leave a white powder. It is GLASS powder)

3. Hold the lens (or other glass object) firmly, preferably don't hold it directly if it is small - clamp it in some kind of rubber-tipped vise grip or clamp.

4. Cut the lens in the place desired, using the diamond saw as a cutting disk. Keep the water flowing on at the cut site. You only need a (constant) trickle - you don't need too much, too much will obscure the cutting area and make it hard to see where you are cutting.

5. Once you have cut the desired part off, you can smooth the cut area (trim any irregularities - remember glass is SHARP) by switching from the diamond saw to the diamond grinder. Use the water trickle when grinding as well.

6. Wash everything off when done; ensure no glass dust remains.

7. Clean up. That's it!

-- DonPapp - 30 Mar 2002