Todd
Sweeney is a contractor for his clients in Holly Springs,
Mississippi. He contacted me on 10/26/10 and over the next 4 months
we gradually worked out the details. He wound up saving $225 from
the more copper I used than predicted in my quote.
This project was for a custom copper 25" wide
grill cover and a
33.5" wide
fire pit
cover, which needed a flange drop down
into the pit 21" wide ISD sleeve made
with 20oz copper to cover
an outdoor gas fire pit in order to keep it clean and dry when not
in use.
Here is some of the shots I sent
them during the fabrication process.

These show the first 3 side formed and held
together with clamps for an 8/12 pitch angle. The drop in frame is
on the right, which will be cemented into the firepit. A stabilizing sleeve
attached to the cover will extend down into the
inside of this sleeve in their fire pit.
 
The handles
are set in front of the cover to get a few shot for the Clients to
help decide their
placement. This may have more seams that what I had done in the
past, but I wanted to make this cover with no exposed fasteners and
a more uniform look. I made some pieces to cap over the seam inside
shown on the right.
 
I marked it with this X for alignment for the
best fit. This shows the drop flange attached to the cover

These premium PVD coated brass handle for a good life-time
finish that will not tarnish and is a lot harder than a lacquer
finish for scratch resistance, since it is really a colored chrome
plating. They run $75 each installed.

 
The right photo is the sides of the grill top
cover. It had to be made with a flat top for clearance when it is in
the open position. I could not seem to find a brass handle that
matched the style. This black handle was all I could find.



After some consideration the clients opted for
this stainless steel handle in stead. I also needed to make a hinged
frame to attach to the counter top.
 
 
After they were finished I packed these up and
sent them. It seems I had not packed them well enough and the grill
cover got dented by the peak of the firepit cover after the foam
cushion between them got dislodged, so they had to send it back for
me to repair.

 
I decided the best way to solve this was to
stretch and dome the flat top a bit, which also helped strengthen
it, so in the end it was for the best. I also made a pair of these 4
gauge copper wire supports to hold up the cover while they use the
grill.
 
Cost: $1,806 shipped to Holly Springs, Mississippi
(saved $225 - more copper used than
quoted)
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