Here
is one of the first copper gazebo roof caps I made several years back
for a large eight sided entry porch roof built onto the front of a house
in Boring, Oregon, just South-East of Portland. We did this in
conjunction with the gutter replacement and some vinyl soffit work they
asked me to perform. This cap alone stands about 4. 5' tall and 2' wide
at the base. I had decided to give this cap a steeple look and
the customer was pleased with the results.
Although, looking back it is a bit of an embarrassment
to me now. In order to save copper here I cut
these 17 separate pieces and sealed them together.
We since feel that it is best to do what we can to minimize the number
of seams for better looks, strength, and far less chance of it leaking
a century later. It is also far too time consuming to seal and
rivet all these seams together, and is simply not worth the copper sheet
metal we saved to do it that way. We also use a lot more rivets
along the seams that I do need to seal, for better strength. More like
good aircraft construction.
It took about 16 square
feet of copper sheet metal to form this roof cap.
The cost of this back in 1999
was around $350 installed. They got a
good deal, but it was the first large roof cap we had made. We now do
our design and fabrication a lot differently, and use a thicker copper
sheet metal as well. Also copper has doubled in cost since then.
In hind-sight:
If I were to put the same labor into this, in sealing all 8 sides
together, I should have made it with tapered panels to give it a smooth
transition from the roof angle up to the tip; starting at the bottom
with the same 8/12 pitch as the roof. It would look better and
made the attachment more stable. I also now use stainless steel screws
instead of nails so it can be removed without damage for reroofing and
then reinstalled. I also integrate a hidden roof vent with a lot of
the roof caps we make these days.

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