This custom copper chimney projects was for our client named Gina Matury who made this diagram on the left for Lake Prairie Homes, LLC at 9308 Chestnut Lane in Munster, IN  46321.  You can phone her at (219) 614-5144. She found our web site and was impressed with our work, so she contacted us for a quote and we worked out this collaborative design concept seen in this diagram.

Her original thought was just to replace the standard galvanized steel roof flange the roofers used with copper. Then have me build this chimney cap made for the top of the round flue pipe seen above. I suggested that we could connect the two with a copper octagonal flue pipe. That way the tarnished copper look would be consistent. She liked that idea and was inspired to make this diagram. Later she mailed in the 1/2 deposit of $1,500 on 2/07, once we had all the details worked out.

Most of the sheet stock we work with is 20oz copper, but the base chamber here is made from this 4' x 8' sheet of thicker 32oz copper sheet metal for added strength to hold the flue pipe sturdy in high wind situations w/o the need for support pipes or guy-wires. The design took the entire sheet from edge to edge top and bottom.

I designed the whole base chamber and roofing flange to be formed in one single piece that is cut and bent to be as seamless as possible again for added strength. Even if it made the fabrication a lot more difficult I place more focus on strength and being water tight, and of course so it looks good as well. It is a bit scary to make sure I have thought this through just right before cutting and bending this very expensive sheet of copper.

It is built in 2 separate parts for easier installation. This is also important for vertical alignment of the flue pipe; incase the base does not set on the roof perfectly level once installed. Then they will screw or rivet these together. The octagonal flue pipe had to be made in 2 pieces, because of the large 14" diameter. I made 6 of the 8 sides from one 36" wide sheet to be able to hide the 2 seams toward the back of the flue. These days I work with 48" wide sheets to be able to form this with just a single seam up the back.

The graduating transition section just under the chimney cap is identical in shape and size as the base transition below the flue pipe. After I built it I slid it down over the flue pipe and riveted in place.

The 16 gauge stainless steel screen also adds to the strength after it is riveted in place behind the corner columns. This stainless steel screen is so hard that it takes a $650 electric sheer just to cut it. It would break the jaws of normal tin snips.

I added another brace in the middle of the roof for added strength. The diagram called for a 3" eave on all sides, but I made this with a 4" eave on the gable ends to better shield out wind driven rains. The roof has a matching 12/12 pitch angle with a 4/12 pitch kick at the bottom. This meant I had to cut the vertical seam to make that bend, so I used some of the scrap 32oz copper to make 4 braces to rivet behind the seam to help hold that 4/12 section of roof up.

Here is the assembled chimney out in the sun before getting crated up for it trip across the country with David and Tia posing for the camera on a tripod on a 10 second delay.

The cost breakdown:
$1,110 for the 55.5# final weight of the base X $20
+ $1,101.60 for 55.08# upper section X $20
+ $105 for 5.25 sq' of stainless steel spark arrest screen X $20 per sq'
= $2,316.60 subtotal
+ $800 for the crate and truck freight to residential w/liftgate service
= $3,116.60 total

Note: She was given a substantial discount for helping come up with this original design that is a great addition to our web site portfolio.

Here is a few shot of the installation we got from Gina:

Hope all is well with you and yours and that you have a Merry Christmas, a happy holiday season and a great new year!

Sincerely
Gina Matury