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Custom
Copper Chimney Cap Page #4 |
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Custom
Copper Chimney Cap Page #4 |
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Company Profile |
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Roof Caps |
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Chimney Caps |
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Scuppers |
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Gutters |
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Below is a few more examples of custom copper chimney caps I've made a while back; placing my primary focus on a strong design with as few seams as possible. There is also links to see more photos and details with a price breakdown of the parts used. I now use a thicker 24oz & 32oz copper for these types of projects. Where the standard in the industry is still just 16oz copper, which are usually soldered together. Which is insane! A CBD fabrication is at least twice as sturdy. Note: As you may know, metal and fuel prices had gone up since then, so I had to raise my prices as well along the way. So keep in mind how the prices listed may not reflect CBD current costs. They are here as a guide to see what those had cost at that time. These also show how I had made lots of improvements since then. |
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For the Goodwin house in NJ we made a pair of Tuscany double & triple arch style, double tier base, 6/12 hipped roof w/internal pans and flue collars.
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Larger chimney cap: 232.5# total weight - 41.6# wood weight - 11.4# SS screen weight = 179.5# copper weight X 0.8 = 143.6 sq' of 20oz copper sheet metal X $30 = 4,308 total for the copper (considerably less than the $6,500 I had originally estimated)
Smaller chimney cap: |
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This was for their Florida home. We are also contracted to build another 4 larger chimney caps for their Buffalo, New York house, along with 8 fancy scuppers, and 2 turret roof caps w/finials.
CBD facebook photo album to see all 237 images from this 21 piece project |
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Chimney Cap w/Weathervane |
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This was for over their fancy clay flue liner that has a natural gas exhaust, so I needed to also build in this a separate fresh are return under the main exhaust weather-head. Cost: $1,019 installed |
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These were custom made for Scott and Antonia Davis in Bedford, New York for their outdoor fireplace first. Then a few months later contracted to make larger rectangular caps for their home as well.  CBD facebook photo album to see all 86 images from this 3 piece project   Cost for all 3 chimney caps: $14,589.67 delivered attachment base ISD: 33.5" X 36.25", or 8.4 sq' 40" X 65.25",or 18.1 sq'& 40" X 85", or 23.6 sq' |
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86.4#Final weight - 20# wood and SS screen weight = 66.4# of copper weight X 0.8 = 53.12 sq' (down from the 68 sq' I had quoted) X $35 per sq' = $1,859.20 for 53.12 sq' of copper work + $149.04 for 12.42 ln' of hardwood in the base + $124.40 for 6.22 sq' of SS spark arrest screen + $175 for custom shipping crate + $275 for truck freight = $2,582.64 total delivered separately . 
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attachment base ISD: 21.25" X 25.5" & 25.25" X 40.75", or 3.76 sq' & 7.22 sq' To see all 57 photos got to CBD Facebook album |
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Cost Breakdown:
Smaller Cap w/roof liner: 92.8# total weight - 20.6# wood weight - 6# SS screen weight = 66.2# total copper weight X 0.8 = 52.96 sq' of 20oz copper in this X $30 per sq' = $1,588.80 for the copper + $157.40 for 7.87 sq' SS screen + $175.35 for 11.69 ln' of wood = $1,921.55 total for the larger chimney cap + $1,291 for the smaller chimney cap = $3,212.55 grand total for both chimney caps w/o crate or freight |
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36" wide cedar mantle covered in 32oz copper w/oversized rivets
(attachment base ISD: 31.75" X 31.75", or 7 sq'. Fire-screen is 48" wide X 39" tall in the center)
Cost Breakdown: Mantle final weight is 33.6# - 13.8# wood weight = 19.8#
Chimney Cap final weight is 105.2# Fire Screen: $600 as quoted Freight costs:
To see all 56 fabrication w/installation photos and read more about this project: |
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(attachment base ISD: 20-7/8" X 56-3/8", or 7.9 sq') Saved $122.30 - for less material used than quoted
$2,615.20 for 95.8 # total 20oz & 24oz copper X $27.30 # + $258.80 for 12.94 sq' - stainless steel screen X $20 + $203.70 for 13.58 ln' - 5/4X6 ipe hardwood frame inside the base skirt x $15 + $250 for crane service (his minimum charge) + $200 for our part in the delivery and installation + $50 for 4.5" wide round plaque $3,577.70 total delivered and installed
To see all 70 fabrication w/installation photos and read more about this project: |
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(attachment base ISD: 25-7/8" X 37-3/4", or 6.82 sq') Saved $470.67 - for more material used than quoted $1,916 for 76.64 total square feet of 20oz & 24oz copper X$25 + $146.80 for 7.34 sq' - stainless steel screen X $20 + $169.35 for 11.29 ln' - 5/4X6 ipe hardwood frame inside the base skirt X $15 + $125 for weathervane support pipe built into the roof +$170 for 24" tall Segmented Globe
+$170
for 18" long flag weathervane
=$3,502.15
sub total
To see all 27 fabrication w/installation photos and read more about this project: |
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  This means the copper weight alone is 109# X 0.8 = 87.2 sq' of 20oz copper left in this project X $30 = $2,616, so we were right on target from the original quote of $2,647.50 $2,616 for 87.2 total square feet of copper X $30 + $342 for 17.1 sq' - stainless steel screen X $20 + $315 for 21 ln' - 5/4X6 ipe hardwood frame inside the base skirt x $15 + $450 for a sturdy large wood crate + $350 truck freight charge for residential delivery w/hydraulic lift-gate service $4,073 total delivered |
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Attachment bases ISD: 23.75" X 38" & 26" X 48.25" The weights and cost breakdown of these pieces are as follows. 1 17.8# - for the smaller unit138.8# - for the larger unit = 256.6# - 46# wood weight = 210.6# X 0.8 = 168.48 sq' of 20oz copper used in all for both. X $30 sq' rate = $5,054.40 - for copper + $236.70 - for 23.67' - 1X6 ipe hardwood frame inside the base skirt x $10 + $280 - for 4 brass door hinges, 40 SS bolts, 80 SS nuts, 50' SS cables, and 8 SS lock pins + $400 for a strong large 38" X 5' X 4.5' tall custom wood crate for both caps + $500 shipping charge to your home w/hydraulic lift-gate service = $6,471.10 total for both delivered. - $4,000 paid = $2,471.10 balance
To see all 36 fabrication photos and read more about this project: Also, you can see a of this chimney cap open from the video the client was nice enough to shoot and share with us:
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 Cost: $5,500 delivered to Vienna, Virginia (attachment base 33" X 80" ISD, or 18.33 sq')
The weight
and cost breakdown was as follows:
To see all 16 fabrication photos and read more about this project: |
Sarkinen's Concave Hipped
Roof
Chimney Cap w/weathervane mount built in
After
building a mantle piece over a year prior I was contracted to make this stylish concave hipped roof design
chimney cap for
Chris & Christine Sarkinen in St. Michael, Minnesota to to cover natural irregular stone
outdoor fireplace. This curved roof line has not internal support,
so we decided to use a thicker 32oz copper on top.
It also needed to have a weathervane support pipe built into the
roof for this stork style weathervane they got from a different Coppersmith who specializes in this sort of custom hammered copper work.
Although, we felt there were a few problems with the design of this
weathervane; as it seems
rather confused. My Wife and I looked up over a hundred images from cartoons to photos of actual storks in flight to see what was bothering
us about this design:
I believe I could have done better for less, but what is done is
done.
The weight
and cost breakdown was as follows:
As stated above the weathervane was supplied by a different vendor.
We gave them a discounted cost for having us make this unique design
we had not done before.
From:
Chris Sarkinen <chris_sarkinen@rdale.o*g>
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St. Michael,
Minnesota
(1/12)
(a) The most noticeable is the small torso they made. It should have been at least 2 to 3 times larger in proportion to the neck and head.
(b) I understand making a silhouette WV, but if you are going to make it 3-D, then it should be 3-D. This has a slender 3-D torso, but that's where it ends.
(c) The neck should be curved more with the head a couple inches higher.
(d) The legs should be hanging down more to show the thighs that seem to be missing.
(e) From what I can see they cannot bring their wings straight up like that w/o breaking their wings or at least hurting themselves. Maybe half that high at a 45 degree angle.
(f) The wings are convex, where they should be concave. I know they may have been thinking they are on a downward stroke, but that still is not a valid argument, since that is not a
truism.
(g) I tested it in the wind outside, but this design will not point in the direction the wind is coming from very well. It does not have more tail than nose. The baby bag in front counter the drag of the wings that are behind the center pole.
(h) The balance is off with it being nose heavy. I am pretty sure they should be made balanced to the center shaft, but if they are not they should be tail heavy. Not nose heavy.
Cost: $2,722.17 delivered
to St. Michael, Minnesota
78.2# - total weight
- 14# - wood in the base
- 4.1# - SS screen
= 60.1# - copper weight
X $25#
rate (special discount for unique design)
= $1,502.50 for the copper
sheet metal
+ $270 for the 180 decorative industrial rivets
+ $116.67 - 5.83 sq' of SS screen
+ $108 - for 9 ln' of 1x6 hardwood inside the base
+ $125 - weathervane support pipe
+ $250 - custom wood crate
+ $350 - truck freight
w/residential delivery
= $2,722.17
grand total
Subject: Flipping you
on your head
Date: 8/5/2019
Hello David!!
Your
work of art is serving us more than well! (Please see attached
picture)
I have an itch to beautify my home that includes copper,
and flipping you on your head. I’d love to commission you to build
us a couple copper window boxes. They’d essentially be the shape of
the handi-work in your picture, but flipped!
One window box would
be more than large, (six feet wide) as it would be under a bank of
three windows. Rest assured, the massive size is warranted as it
would sit on a large elevation of our garage that is otherwise
boring and unsightly. The second window box would be half the size
as it would sit under a three foot window. (I know these
measurements are on the vague side....this email is meant as a
conversation starter)
I’m hoping this proposal has some
mystique/appeal as it’s a bit out of the mainstream!!
Looking
forward to your thoughts—Chris and Christine
Morgan's Low Profile
Chimney Cap
I made this stylish low profile design w/6/12
hipped roof for Jim Morgan in Bend, Oregon to go over their wood
chimney box that is covered with natural irregular stone, so it has
a sealed internal pan to divert the rain water back outside that
could get blown in through the screen.
The attachment base was built 35.75" X 42" ISD, and has a 1x6
hardwood base inside for a 37.5" X 43.75" OSD. The roof is 41.25" X
48" OSD. The final weight was 119.4#, which 93# was just copper =
74.4 sq' of the 20oz copper we used X $25 sq' = $1,860 for the
copper portion alone.
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small hole
screen for a natural gas fireplace
Bend,
Oregon (12/11)
Cost: $2,126.52 client pick up
Lawton's Pair of
Simplified Tuscany arch style
(attachment base 28" X 38" ISD)
Cost: $4,439.20 delivered
to Saunderstown, Rhode Island
From: "Bruce Lawton" <bruton@cox.n*t>
I Will admit that when we opened the crate our
reaction was one of '¯good grief, what have we done... they look so
big!'.¯ But once installed, the cap proportions are well in keeping
with the house shape and the extended cap roof line fits right in
with the house roof line. Our conclusion is you get a 10 out of 10
score for looks, design, quality of construction.
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Saunderstown, Rhode Island
(5/11)
This was a
pair of simplified Tuscany arch style chimney caps they
wanted, yet simplified to control the cost to fit within their
budget. Can you tell what the differences are? One detail that is
very different is how this is the first I made with an elongated
ridgeline to resemble a gable end roof like more to fit in with
their house.
Date: Wed, 25 May
Subject: install complete
Hi David,
Wanted you to know that the caps were installed today. The weather
was fine and the fit on both chimneys was absolutely perfect. Nancy
and I are very pleased with the look of the caps, and the installers
were all impressed with the quality of construction and the ease of
installation.
Regards,
Bruce and Nancy
Raban's
Simple Square Flue Liner Mounted
This was a small simple square chimney cap I was asked to build for
a Contractor in Kent, Washington. This was designed to just slide
down over the flue liner sticking up out of the top of their
client's chimney.
(attachment base 12.25" ISD)
Cost: $461.25 delivered to
Kent, Washington
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Kent,
Washington
(10/10)
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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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