Half Wall with Step Down Glass Block Top

Project 2:   Half Wall W/ Step-Down Glass Block Top

Materials & Tools:
  • 2x4x8’s Select Choice Fir
  • 1x6x8 Clear Pine
  • ½˝ Drywall
  • 8˝x8˝x4˝ Glass Block (We used Pittsburgh Corning Glass Block)
  • 8x8x4 Glass Corner Block 
  • 8x8x4 Glass End Block
  • Horizontal & Vertical Spacers
  • Block Anchors
  • Glass Block Sealant (comes in tubes)
  • Glass Block Surface Grout
                 •••
  • Miter Saw, Circular Saw
  • Pneumatic Framing Gun W/ 3˝ Framing Nails
  • Pneumatic 18 Gauge Nail Gun W/ 2˝ nails  
  • Speed Square & Tape Measure
  • Hand Snips, Utility Knife
  • Screw Gun W/ 2 - 3˝  Wood Screws
  • 4ˊ level & Torpedo Level
  • Rubber Mallet, Rubber Float & Rubber Gloves
  • Caulk Gun 
  • Bucket & Grout Sponge

Note:  The sizes & quantities of the materials listed above will vary depending on the size of the project.

We used Pittsburgh Corning Glass Block for our project

Step by Step

Building the Half Wall...
  1. Measure the area where you will be building the half (knee) wall.  Figure out the overall dimensions (width & height) of your half wall W/ glass block top.  Once you know the overall dimensions of the entire wall you can then decide on the dimensions of the half wall portion, on top of which the glass block will sit.   Chalk a line on the floor where your wall will sit & prep the area.
  2. Cut the studs, top & bottom plates to match the dimensions of your half wall. Cut the 2x4’s using the miter or circular saw. Note:  The # of studs you’ll need will be determined by the length of your wall.
  3. Using the framing gun, nail the studs to the top & bottom plates.  Space the studs every 16˝ along the top & bottom plates. 
  4. Set the half wall frame in place against the line you chalked on the floor.  Attach the half wall frame to the floor and side wall (the wall it’s up against) using the screw gun W/ 3˝ wood screws. Note:  If you have a concrete floor, use a hammer drill W/ concrete drill bit & 3˝ concrete screws to secure the bottom plate.
  5. Using a Utility Knife, cut the ½˝ drywall to fit your half wall.  Secure the drywall to the studs with the screw gun and 1½˝ coarse drywall screws.  Keep the top edge of the drywall flush with the top of the top plate.Fill the screw holes with joint compound, let dry, then sand smooth.
  6. If you dry walled both sides of your half wall, the total thickness of the wall will be 4½˝.  Rip the 1x6 down to a width of 5˝ which will give you a Ό˝ overhang on each side.  Cut and attach the 1x5 clear pine to the unfinished top and end of the wall.  Cut the end of each board at a 45˚ angle where they meet at the corner.  Attach the 1x5 pieces by face nailing them into the exposed 2x4’s with the 18 gauge nail gun and 2˝ nails.  Apply wood putty to the nail holes & sand smooth.

Installing the Glass Block...
  1. Test fit the glass blocks on top of the 1x5 and up the wall using the spacers.  Mark where the locations where the blocks (the last one on the 1x6 & the last one up the wall) end.  Draw a center line up the wall & down the 1x5 to these marks.  
  2. Cut the horizontal spacer to length and place it on the 1x6 centered on the line.  Draw a line along both sides of the spacer.  Remove the spacer and apply two Ό˝ beads of sealant, Ό˝ inside the traced outline of the spacer you removed.
  3. Reinstall the horizontal spacer, with an anchor inserted, and press it into the sealant.  Do not attach the anchor with screws.  Note:  Check the product instructions for more details on the anchors.
  4. Line up the first row of blocks and one end block to install on top of the horizontal spacer. Apply two Ό” beads of sealant across the top of the blocks, just behind the raised edges. Note: These blocks will be turned over when installed so the sealant beads will contact the bottom horizontal spacer. Always apply the sealant to the blocks, not the horizontal spacer.
  5. Install the glass blocks and vertical spacers. 
  • Apply four 1/2” dabs of sealant to a vertical spacer, 2” from each corner. 
  • Press the vertical spacer into place over the anchor. 
  • Apply four 2” dabs of sealant to the vertical spacer, 2” in from each corner. 
  • Install the first block with the sealant beads down. Push the block firmly against the jamb and sill.
  • Apply four 1/2” dabs of sealant to the side of the first block, 1/2” in from each corner and press a vertical spacer into place on the sealant dabs. 
  • Apply four 1/2” dabs of sealant to the vertical spacer, 2” in from each corner. Install the next block with the sealant beads down. 
  • Continue installing blocks and vertical spacers in this manner to complete the first row.
      6.  Apply two 1/4” beads of sealant on top of the first row of blocks, just behind the raised edges.
      7.  Install the second 31” horizontal spacer on top of the first row of block, with an anchor inserted into the jamb end. Make sure the spacer fits firmly on the glass blocks. Press the spacer down onto the sealant.
      8.  Align the V notch in the anchor with the plumb line drawn on the jamb, and attach the anchor using the screws provided in the anchor pack.
      9.  Remove any excess sealant from the horizontal and vertical joints. Adjust the size of sealant beads to prevent squeeze out (keep joint area clean of sealant). Do not change the location of the beads of sealant.
      10.  Continue installing the block in this manner until the last block is set.  

Apply the Grout...
  1. Mix the grout according to the instructions.
  2. Apply the grout to the glass block joints using the rubber float.
  3. Using clean water and a damp sponge, wipe up any excess grout making sure to wipe in circular motion.  Let the grout dry and wipe film off blocks.

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