The soldered piece is removed and dipped in diluted sulphuric acid for sometime. Then, the mica sheet is peeled off using the Chimtas. To remove any crimps on the gold sheet it is placed face down on a hard surface and the Vada is lightly hammered.
Pieces of the solidified Ral are placed within the Vada on the gold sheet. This is then heated for the Ral to melt. The melting of the Ral is done by placing the filled wire and gold sheet on a flat iron sheet and placing a mica sheet over the Vada and gold sheet. This is placed in the furnace. The furnace is made of iron sheets. Coal is used as a fuel and pieces of burning coal are held over the job with tongs and provide heat from above. A blow pipe is sometimes used for direct heating. The softened Ral is spread all over by pressing it. It is lightly hammered to pack tightly within the Vada and gold sheet. Thus, the gold sheet acquires a suitable base on which it can be worked upon. The Ral is then suddenly cooled by dipping in water to set it. The extra gold is clipped-off form the sides of the Vada. The outer edges of the Vada are then rubbed on a grinding stone. The wooden block with the Ral is heated to melt the Ral so that it can be spread and flattened. The A wet piece of thick paper put on it cool and is left thus. Now the decoration of the gold sheet starts. The first stage, Kardarna, is when just an outline of the motif is etched on the gold sheet. The second stage involves detailing i.e. eyes, ornaments etc. This is called Cheerna. The third stage is when the Jali is cut. This is a delicate process and the waste is collected in a small piece of paper. The waste is in the form of gold sheet plus Ral which is later melted. The gold melts and the Ral burns out. After cutting the Jali, the block is heated so that the Ral melts a little and when it is melting, the Jali is lifted slowly with a tweezers. After this the glass is etched with the same metal as in gold in negative i.e. the portion which is left in gold is etched out in glass. Then a solution is applied to the gold Jali and the Jali is placed on the gold etched glass and the glass is heated. This fixes the gold on glass.Traditional method: A glass piece is cut with a diamond cutter to a suitable shape and size to be placed inside the Vada. This arrangement is covered on the side of the gold work with a mica sheet (the mica acts as a non stick surface). A heavy steel stab is placed over the mica sheet. This whole structure is placed again upon a similar sheet slab in the furnace. Due to heat and pressure of the steel block it is probable that the gold is fused with the glass. It happens in a manner in which the gold and the base glass acquire a common surface with no two distinguishable levels.
The work is taken out of the furnace after the glass is seen to turn red hot for a few seconds. It then left for cooling. Contemporary method: The glass piece to be used is first etched with the design with the help of a diamond cutter. This design is transferred on the gold sheet; by holding the etched side of the glass in a non-oxidizing (yellow) flame, it is covered with a layer of carbon (soot). The etched surface is then pressed on the gold sheet to get a print on it with help of this reference a duplicate of the design is on the gold sheet which gives the Jali work in gold. FIXING OF THE JALI WORK ON ETCHED GLASS The etched surface of the glass is coated with a solution which possibly acts as a adhesive when heated. The gold work with the Vada is placed on the etching and fit slowly. This arrangement is placed in the furnace. After the gold fuses with the glass it is removed from the furnace and left to cool. The gold fixes with a level below the surface of the base glass and the etched edge of the glass can be easily felt with ones fingers. FIXING OF THE GLASS IN GHAR After the gold plated Ghar is ready, the base is fitted with iron wires (stuck with adhesives; synthetic) to give the glass support inside the Vada the glass with gold is then placed and the Vada top is rested on the glass. In case the piece has to be stung holes are drilled in the sides of the Vada for the string to pass through. Only gold sheets of the highest purity are used, for this lends itself to the thewa technique. The artisans treat all gold to remove impurities before rolling out and cutting the sheets, usually of 40 gauge thickness. 'As the work requires intricate detailing and skilful fusion of the gold into the glass base the wastage is high', says Ganpat Soni, a National Award winner and master in the technique of thewa. 'Overheating can break the glass or melt the gold. Alternatively, if not treated properly the gold filigree does not fuse well and soon comes off.' Talking about the initial struggles Soni says: 'It is only after years of intensive experimentation and many failures that the technique can be perfected.' Soni now guarantees 98 per cent quality. The artisans at Rampura have been using Belgian glass, from old windowpanes of houses and buildings, as the base for thewa articles; however, this source has now been exhausted and finding glass with the right colours is becoming increasingly difficult. As a result, thewa pieces can now be found in a new range of colours and materials: lemons, whites, blacks -some original, some obtained by using plastics. Artisans are also experimenting with other metals, including silver.The craftsmen are also called for exhibitions in different cities where they sell their products.
The colours are of the earth, of stones. The modern patola often has the designs are created in the weft threads only. This is less labour intensive and hence less expensive.