The Archadeck Gazebo Cap
Des Moines, Iowa (6/03)

Photos and Description Page

Updated 7-7-2004

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This solid 20oz copper cap was custom made for a company called Archadeck, for their Iowa office. They had built a gazebo for one of their local clients, thinking that a cap would be simple to acquire.  They waited till near completion to try and get one.  But after a long search on the web, he told me that we were the only craftsman out there who offers to fabricate the type of caps that they desired.

The gazebo had a 14/12 pitch roof.  We fabricated the cap to have  more of a 16/12 pitch, so it would be sure to not have a gap at the base when placed on the gazebo roof.  Just incase either of us were off with our specifications.

This picture clearly shows the 3/4" safety hem we fold over the bottom edge.  This helps to keep the cap straight and uniform and for safer handling during installation.

We can do a scrolled bottom edge.  Depending on how intricate the scrolled edge is, would determine the addition of this safety hem. (see below for some examples of those options).

As you can see here, this cap only has one seam.  We then rivet the seam tight with copper rivets that have brass mandrels.  The rivets that we can access from the inside are then flatten with a hammer over an anvil.

A bead of caulk is then run on the inside of the cap and over the rivets.  We press it in tight with our fingers to make sure we did not miss a spot.  After letting it dry for a while, it gets covered with some gaffer's cloth tape.

We clean any excess caulk on the outside with paint thinner, so there is nothing to interfere with the outside patina of the copper.  Once it has darkened (which usually only takes a couple months), the rivets will hardly be noticeable.  It is still a good idea to set the cap with the rivets facing the least visible side of the gazebo roof.

The 8 holes are then pre-drilled for the installers to nail it to the roof, to prevent them from denting the copper when driving the copper nails through this copper sheet metal.  The 1.5" or 2" copper nails are supplied, and can be found taped inside the cap (seen above).

The weight is not the issue with the cost of shipping.  The size of the package can be more of an issue that determines the cost.  If I go a little over this (what size) size, the shipper will add an additional $50 for oversize packages.

I do not feel that a simple cardboard box offers enough protection for these copper caps.  It is true, it does not cost very much to insure the items shipped, but to have my client need to deal with their insurance company to seek resolution would be a rather time consuming and an unpleasant hassle.  So I feel it important to go the extra mile at my end, to avoid the need for such problems.  I spend a couple more hours to custom make an aluminum box like this one shown here, to house the caps in, for a safer trip.

Here is a side view of the assembled cap, so you can see the height of it.  It measured 12" tall and 18" wide at the base.  It is sitting on the custom aluminum sheet metal box I made for it's safe journey to Des Moines, Iowa.  We cover the aluminum box with cardboard so the shipper does not have an issue with the packaging method.

It took about 8 square feet of copper to form this cap. 
Cap fabrication cost: $160. 
Custom aluminum box: $50
Shipping: $50
For a total of $260.

This photo on the right shows another form of packaging I use.  This is framed with 1x2 boards that are screwed together onto the four 2x2s in the corners.

I then staples the cardboard to the wood frame for a custom sized box to best fit the item to be shipped.

It is filled with these 1" sheets of Styrofoam, with smaller pieces on top to fill in the gaps.

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Click this photo to go back to the
Custom Copper Roof Cap main page.

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Below is a photo of our
Better Business Bureau's
NW Business Integrity Award
for the year 1998

1999 Better Business Award

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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