This copper chimney cap projects is for Brad and Pam Stone in Summit, New Jersey. It is actually for their outdoor fireplace. He may have me build some chimney caps for his house as well that match this design. The inside of the base is 31.25".

This shows the flat sheet of copper cut out to form the base/skirt with all the bends and cuts to be made. Then I bent them into shape and cut the wood support frame using 1x6 oak hardwood boards this time for inside for added strength, weight, and to thread the screws through for fastening it to the stone covered chimney. Then I seal the 2 halves together to form the full base/skirt.

Here is the flange attached over the base with a channel to hold the stainless steel screen in place along the bottom edge. I made a rise in the inside to help the rain water that might get blown through the screen to shed outwards. This also helps add a lot of strength along this edge with the double sheet of copper.

Here is the 2 pieces of sheet metal for the arched columns being drawn out and cut where needed.

Then the arched column ways get formed and built. The bottom of the columns are angled to fit over the base at the 6/12 pitch that will shed the rain and debris that may get in under the eaves. then a liner is attached up inside each arch way.

The stainless steel screens are riveted in behind the columns which helps add a lot of strength and stability to these columns. Then the decorative piping is added to the outside of the columns riveted on from inside. This decorative trim is very trick  and time consuming to form just right and attach to the columns, but adds a nice touch of class.

The eave is attached over these columns that I will attach the roof to. Then finishing the roof braces built over the eaves to help support the eaves from sagging under the weight of the roof and snow that will settle on top.

I then cover this with a 3 part roof skin. I covered it a bit different than I had done in the past; in stead of making the seams over each corner bend, I covered each end and then draped a rectangular sheet over the center for a nice clean look that is more seamless.

Here is the roof skins to go over the bracing and attach to the eaves to make a nice sturdy structure. I made this to resemble the Tuscan style I made to Mr. Gross, yet it will have no eave past the base and it has a deeper set stainless steel screen in the archway than I had made in the past. It has solid oak boards inside the base skirt.

Here it is finished sitting over the custom crate base.

Here is the crate to carry the chimney cap safely across the country in a large semi truck. The left photo shows the 5 sided top of the crate laying on it's side with one wood cover to be attached.

The Installation

We exchanged 32 e-mails in the course of working out all these details and providing them with 40 digital photos of the progress. Here is the feedback from this client:

Cost for this project: $2,503.20 w/shipping

186# total weight w/crate
96# total weight of just the chimney cap
- 16.5# wood
- 3.75# SS screen
= 75.75# of copper
x .8 = 60.6 sq' of copper sheet metal
112.2 x $30 = $1,818

 $1,818.00 - copper
+ $122.20 - SS screen (6.11 sq' x $20)
+ $88.00 - 1x6 hardwood (11' x $8)
+ $250.00 - wood crate
+ $225.00 - shipping - residential with lift-gate

$2,503.20 total
- $1,500 deposit paid
= $1,003.20 balance