The 4 column frame that supports the roof over the base is 10" tall with a 9" tall vent opening on all 4 sides that are 25.5" wide on the long sides. The design called for a long 5" eave overhang past the base, so it was 9" from the screen out to the roof edge. The final weight was 60lb, which translates into 48 square feet of sheet meal used in this fabrication.

Here is the 28" x 45" long roof framework being constructed with another shot looking up under the 9" wide eave. If you look at the larger images that these smaller images link to; you can see the clear vinyl protective film over the copper sheet metal. I built these 3" wide roof braces to support the flat roof panels from impacts and snow loads that could occur.

Once assembled it was structurally solid feeling and did not seem to have any flex to it when lifted up on one corner. Here is the custom wood crate being built over the chimney cap and skinned with a thin hardwood plywood on the sides. We predrilled the holes in the boards before gluing and screwing it together.

We had estimated this chimney cap fabrication to require less than 35 square feet of copper total. We did weigh it to see if there would be any discount after we were done, but the weight was actually 11 square feet over the estimate, not including any of the cut-off waste needed to build this. I commonly tend to over build these creations to make sure they will be as strong as I feel they may need to be. This means our client got $330 worth of free copper work in this one small project.

Total Cost: $1,940 with crate and truck delivery