CBD's Copper Chimney Caps Photopage #1

Below is a few more examples of the early custom copper chimney caps I've made; placing primary focus on a strong design w/as few seams as possible. There's also links to see more photos and details w/price breakdown of the parts used for most projects.

Note: We do not intend to be misleading with prices listed on these web pages for chimney caps made prior to to 2006, but with metal and fuel prices having doubled since then we have needed to compensate as well. So keep in mind how the prices listed may not reflect the current cost. They are here as a guide to see what these cost at that time.

The Tullier Custom 20oz Copper Chimney Cap
Portland, Oregon (6-04)

Here is a copper chimney cap we custom fabricated for a local client: Paul and Sherri Tullier, 1160 N. W. 91, Portland, Oregon 97225. It was needed since the concrete on top was cracking and the steel plates that support the top layer of bricks was rusting and causing terrible rust streaks down the side of the chimney and on their metal roof

This picture shows the preparation for the solid 20oz copper sheet metal used to fabricate a cap for this this brick chimney cap. This chimney measures 11' 9" long, and 1' 4.75" wide.

We used a wire brush to scrape off the moss over the chimney top and on the sides. We then treated it with a weather seal chemical.

We bevel cut the top side of this pre-primed 12' long 5/4 x 6 spruce to conform to the angle of the copper chimney cap we made. This will support the center, to give the cap a bit of a pitch, so there is not any standing water, and even debris should shed off it. It will also better match the pitch of their metal roof.

We then covered the board and cement with two layers of 30lb saturated roofing felt, to give a gentle base for the copper to rest on, so there is no chance for the concrete to chafe the copper from underneath. We stapled it in place onto the board. We then placed the copper chimney cap on top.

It took a sheet of copper that was 29" wide and 10' long, along with another 3' x 29" to finish the whole length, as it needed to be 12' 3" long, in order to give it a 3" overhang off each end. The width of the cap is 20.25" once it was bent into shape for strength. We made 8 - 3.5" wide straps (shown below) to go inside each vent you see here to secure the copper cap to the chimney top.

Since most of the cost is the fabrication, why not use a metal that will last? The older caps shown here are made with 16oz copper, but we recently found a source for solid 20oz copper sheets that are 3' x 10', so there is less need for any seems and it will be more rigid, as well as heavier, so the cap will be more stable in high winds. It will add to the cost of course, but we feel it is well worth the added cost.

The total cost for this 20oz copper chimney cap was only $739.20 installed. The cost was calculated for the 36.96 square feet of 20oz copper to make this chimney cap at only $20 per square foot, since it was such a simple design and had no screened vents. Other than handling such a large sheet of copper to make this long chimney cap, it was not too tricky to make and install.

Cost: $739.20 installed

To find a reliable contractors in your area that your neighbors have used and reviewed

The Hubanks Custom 24 Gage Stainless Steel Chimney Flue Cover
Washington, DC (4-04)

Here is a stainless steel chimney cap we custom fabricated for a client: Paul Hubanks of Washington DC. Paul and I spent about a month passing 41 e-mails back and forth, in order to work out this solution to his problem. To be sure to keep out the rain from the surrounding area of that aluminum flex-pipe liner he just had installed even on high wind days, we worked out a plan for a stainless steel flue liner cap to go under his stainless steel chimney cap shown above left.

To the left you will see the cap we designed and fabricated. We do not have a spot welder, since we rarely work in stainless steel. We had to design it to seal out the rain while just being riveted together, and it had to accommodate the other cap to go over it. The stainless steel is a lot harder to drill through, even though it is a much thinner sheet metal. Below is the 8 part sections that made up this one little cap.

Cost: $300 php for both

The Wasserman Custom 16oz Copper Chimney Cap
Portland, Oregon (2-02)

We custom built this simple designed chimney cap in solid 16oz copper and installed it (2-02) for a client: Gary Wasserman 6242 SW Burlingame Ave, Portland, OR 97201.

It is to cover their flat galvanized steel pan that covers the wood chimney enclosure shown below, to prevent further rust forming. This way there is not going to be any more standing water on the steel pan. We used copper rivets for assembly, and stainless steel screws to fasten it to the top of the chimney box.

Cost: $900 installed

Below are a few more examples of our earlier custom chimney cap work

We custom built this chimney cap in solid 16oz copper and installed it in May of 1996. I used copper rivets and stainless steel bolts to fasten it to the top of the 2 flue brick chimney. It represents some of the most demanding work that we do.

This went on a house that was built up on the West Hills in Portland Oregon. It is in a high wind area, so we had to make sure it was designed to withstand 100 mph winds, and yet be removable for cleaning the chimney flues.

Cost: $900 installed

Here is a 2 flue chimney in the windy city of Gresham Oregon. We first did the aluminum flashing at the base. but latter they reported experiencing some leaking into the house. Upon inspection I could not find anything wrong with the flashing I had installed. I performed a leak test for a few weeks by wrapping a tarp over the chimney, leaving the flashing at the base of the chimney exposed.

This was to test if the water was actually getting in from inside the chimney, before they had to go through the expense of getting a chimney cap. It proved to be the case, and it has solved their issue since 1996. Cost break down: Step-flashing: $150, counter-flashing: $475, leak test: $150, chimney cap: $900. $1,675 total.

This is the same chimney from a lower side view. It is hard to see in these pictures, but there is a long screened area on each side, as well as the screened holes in the ends. The screens are solid copper as well. They are used to reduce any hot cinder risk and to keep any critters out, including bees.

Cost: $900 installed

Here is a single flue chimney. I rebuilt this from the roof line up, as the old one was made out of large cinder blocks and was falling apart. I rebuilt it up about 5 feet high, along with the needed shingle repair, step-flashing, counter flashing, and a simple but cute cap I made. The flashing and cap were made with a clay red pre-painted aluminum. The chimney was only used now for natural gas, so the heat requirements are a lot less. It was out in Sandy, Oregon.

Cost breakdown:

$150 shingle repair and replacement
$100 Step-flashing
$200 Counter-flashing
$540 Chimney
$300 cap

$1,290 Total

Cost breakdown:
$300 tear-down
$100 shingle replacement
$100 Step-flashing
$200 Counter-flashing
$1,100 Chimney
$750 Scaffolding
$75 brace
$250 cap
Total $2,875

This house is in Southeast Portland, Oregon. This is a custom chimney cover I made, after I had rebuilt the chimney from the roof line up, some 10+ feet. Because it was so tall and narrow, I installed this galvanized pipe as a brace, mortared in through the center of the chimney to the other side, with a flange screwed onto the outside. It has a steep roof with it, and the basic rule is that the top of the chimney needs to be 2 feet higher than any roof area that is less than 10 feet away. I corrected this issue, as well as fixing the problem of it being ready to fall down. Instead of just mortaring the top, like all the other brick masons, we topped it off with this clay red painted aluminum sheet metal. It has cement filling it, and screws mortared in to keep it in place. We quickly installed it before the cement set.

The cement is formed near the shape of the cap, and then the cap is pressed and tapped onto it for a tight fit, so the cement fills into each crevice of the cover.

It also has the advantage of giving the chimney a real working drip edge. It has galvanized screws pressed into holes drilled into the center section, and driven into the cement. this way the cap cannot blow off in high wind.

This one to the right is on a house in West Linn. I can also make this cap in copper as well. This chimney is only used for this thin walled aluminum flex pipe for natural gas venting, so high heat is not an issue.