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Custom Copper Chimney Cap Details and Photo Page #3 |
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Custom Copper Chimney Cap Details and Photo Page #3 |
Updated 5-3-2008
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Below is a few more examples of 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. |
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The Takhar
Double Walled Shroud, Flue-pipe, |
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This fireplace hood was a collaborative design with our client named Harry Takhar in Bemidji, Minnesota to keep with a square looking design. It has a 7.5/12 pitch hipped double layer hood design. The base rim here is 4' 9" wide square, but the outer shell is 5' 2.5" wide. There is a 4" tall rim on the outer shell. The two layers are spaced 2.5" apart with the internal bracing you see mounted on the liner and later attached to the outer shell. It was made to be mounted over an outdoor fireplace that is under a breezeway roof between a pair of enclosed gazebos.
You can see here the white vinyl covered outer shell that is a thicker 24oz copper from a different supplier than we buy most of our copper from. Once assembled it was structurally solid feeling and did not seem to have any flex to it. It is resting on a shipping crate waiting to be picked up by the trucking company Roadrunner/Dawes, which contains a large turret roof cap. 145 lb - Cost: $2,900 |
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Here is the square 8' 10" tall double walled flue pipe he requested we make for the hood to deliver the exhaust safely out through the roof. It weighs just over 100#, which translates to 80.4 square feet of the 20oz copper sheet metal we use. It took 3 sheets that are 3'x 10' of copper to make this one flue pipe. 101 lb - Cost: $2,020 |
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48 lb - Cost: $960 |
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Here is the 37.5" wide fireplace cover lid we got for him and attached this brass handle onto. The second photo is a close-up of a stainless steel eye with a 4 gauge copper wire wrapped over it. To just wrap 2" of the end that wire took 3' of a smaller diameter 14 gauge copper wire. We shipped a spool of 100' of the thicker copper wire, and 20 sets of the thinner wrap wire with this example piece. It is to support the hood under the roof beams. We also sent a dozen 1/4" thick SS eye hooks to connect the copper support wire to the beams ahead. Cost: $375 & $326 |
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Total Cost for this 6 part assembly: $7,831 w/crate &
shipping
To see more photos and read more details
of it's construction: |
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The Kensington 28 Chimney Caps |
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We were contracted to build 28 copper chimney cap/shrouds with 18 gauge stainless steel screens to cover these typical small caps on an apartment complex in Sunnyvale California.
This chimney shroud project was designed by RSS Architecture. They first had a wood proto-type made with just the 4 side walls and installed to see how it would look from the ground. Then they had a non-functional galvanized steel shroud built for 1/3 the cost we charged for these copper units. Our's was a much better deal considering the copper costs over 6 times as much as steel, not to mention our improved design required about twice as much sheet metal. So if we had made them the same way, they would have only cost $750 each for copper, which if built well will last over a century.
You
can read even more about these and see lots
After reviewing their design I offered several improvements. We offered some modifications to improve it's functionality and looks with adding a sealed roof over the top and 3" deep set inner walls for the side screened vents to add strength visually as well as structurally. It took several diagram revisions to get the final design locked down over the coarse of a couple months. The right photo shows the same unit after only 3 months after installation, having turned this satin brown already.
They are 46.5" wide and 37.5" high. Several inches larger than the earlier proto-type they had built in steel. There is also a tapered pan built inside to shed rain that might blow in through the screened vents. We offered to build one unit and ship it separately for installation before we continue building the rest of these units to make sure there was no need for design alterations. No alterations were needed.
Total cost: $45,279.20 delivered
personally |
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Trainor Chimney Cap |
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This chimney cap is for a client named Teresa S. Trainor in Fairhope, Alabama. It has a 6/12 pitch hipped roof made for it. The base is 71.5" x 44". There is a pan built inside to shed rain that might blow inside under the roof. The cap was co-designed by us and the client. It took several diagram revisions to get the final design locked down.
As you see in the photos above I recreated this diagram with great accuracy and detail. I weighed this to see what was the actual amount of copper used in this fabrication; and without the wood frame it weighed 182.5lb. Which divided by 1.25 equals 145.6 square feet of 20oz copper used in this chimney cap. We multiply this by our base rate of $25 which totaled $3,640 + $300 for the large wooden frame base. We spent another $65 on the engraved plaque she had requested be applied to the cap.
There was a ceiling on the price of $4k, but we still wound up using a good deal more copper in this chimney cap than we had estimated. So the building of the wood crate and the $300 shipping charge was pretty much free of charge to the customer. We worked on this for over 3 weeks and they saved about $1,000 on this.
Cost: $4,000 w/crate &
shipping |
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The
Silbernagel Custom 20oz
Copper Chimney Caps |
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This chimney cap was built for a local client named Tom Silbernagel in Dundee, Oregon. It has a 6/12 pitch hipped roof to match the house. The base is 34" x 40". There is a 4" eave past the base. There is an inner pan to shed rain that might blow in through the copper screen.
I made this solid wooden saddle for the chimney cap to rest on. It was made of 8 overlapping pre-primed 5/4 x 6 boards. They are screwed and glued together with Gorilla Glue. The boards were angle cut at the top for a more gentle support under the copper base and to over hang the stucco.
I weighed the cap to see what the actual amount of copper used was. Without the wood it weighed 81.5lb. Which divided by 1.25 equaled 65.2 square feet of 20oz copper in this chimney cap. He got a good deal on the copper screening, since it does not weigh much, but takes special care to install. We multiplied this amount by our base rate of $25 which totaled $1,630 + $150 for the larger wood frame, and another $100 for the upper wood frame. Installation was an additional $150. Cost: $2,030 installed I had also made some custom copper flashing for this client several months earlier. |
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The
LEA Design Custom Copper Chimney Caps |
This was the first Tuscan archway style chimney cap I built for a non-local client Lea Pascoe of LEA Design in Santa Ana, California. This chimney cap is designed to go over a stucco chimney with a metal chimney flue pipe in the middle of a red tile roof. The base shown in the first photo is 25.25" x 26.25" wide not counting the bottom drip-edge flange. It is made with one piece of copper folded over at the corners with a single overlapping seam on the back corner. The corner roof supports are also made from a single sheet of copper with only one seam for added strength and a smooth clean look. It weighs about 49lb with the screening installed. This has taken over 3 full days work, plus the time to build the custom crate and wrap it for shipping.
The roof for this cap is a 10/12 pitch pyramid style hipped roof that will be 28.5" x 30" wide. Ms, Pascoe is getting a good deal on this set of chimney caps, for coming up with such unique attractive designs. Cost: $1,193.75 w/crate & shipping to a residence |
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The LEA Design King's Crown Chimney Cap (1/06) |
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Here is the other chimney flue cap ordered along with the above mentioned cap. It was designed by LEA Designs to looks like this King's Crown style lamp photo above with a weathervane mast support pipe built in the center. This is the first Chimney cap I've been asked to make with a weathervane support in it.
I used 20oz copper for center section of this chimney cap, but I used a thicker 32oz copper for the outside circular crown points and the 8 support straps below for added strength. It has 6 rivets attaching each strap to the rim of the cap, but are hidden from view; hidden with another layer of 20oz copper over-lay on the upper half of the strap to make this curl out past the cap rim. There are oval solid brass knobs on the tips of the crown.
The screen is some thin copper expanded mesh that was from 6" gutter screens. This was before I started using the stainless steel spark arrest screens I use now that is stronger and has larger holes. Cost: $812.60 w/crate & shipping to a residence |
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On to Chimney Caps page 2 Or back to |
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Below is a photo of our |
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We were also a 1997 finalist for this same award. See our referral web page to see how we managed to be honored with this special award |
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