CBD's Dome Cupola Roof Harneck

This custom solid 20oz copper sheet metal roof cap was made for our client named Ron Harneck; Estimator for Huntoon Lumber Co. Inc. Marlette, Michigan 48453
Phone 989-635-7548, Fax 989-635-3908 www.huntoon.doitbest.com

It was ordered for their client who needed a dome shaped octagonal roof cap for over a cupola on their gazebo they had built. It was to be 30" wide in the shape of a beach ball. I do not often see lumber yards go to this kind of trouble for their clients to research the best options and negotiate for such unusual one-time requests. If you happen to live in the Marlette, Michigan area he is your man.

I designed his roof with the support an actual inflatable beach ball I bought to assist me in getting the math just right for this hemisphere shape I needed to make.

I then made a pair of aluminum templates to tape together to make sure it would have just the right curve. I made some adjustments and made a third template to outline this shape with the inner ridge and the overlapping tabs. This shows the 8 separate sections cut out with 4 of them bent and formed into this shape. I made it to have a 1.25" wide inner ridge to help add strength to support the dome from impacts, since this would remain hollow inside.

Here is the 8 assembled pieces to form this roof cap. It was a wrestle to get the last 2 sections in just right. The beach ball I bought for this said it was a 20" inflated size ball, but turned out to be about only 14" wide. I calculated the measurements I got from that ball by 2.25. The final roof cap outside diameter wound up being only 29.75" wide, which made the inside diameter even less. It seems I should have multiplied those numbers by 2.26 in stead.

I contacted Ron to see if this would still work for them. He assured me they can router the top edge of the cupola if needed to make it work. I made a small center cap to make sure the rain water will shed off the top.

I then carefully caulked under this on all the seams and over each rivet to make sure it was sealed water tight. Other than the math coming out slightly smaller than I had wanted, I feel it turned out pretty good. It was certainly sturdy.

I had given Ron a very good deal for this project, since I had never made a dome roof before and wanted to have this to show on our web site. This project wound up taking over 6 square feet more copper than estimated and the shipping was $97, so I did not make much on this. It should have cost $387.75 more at the same low rate per square foot I had quoted.

The zip-lock bag taped on the outside has the stainless steel attachment screws with a few extra, alignment nails, and a new #3 Phillips tip for the SS screws. I normally pre-drilled the screw holes and set the SS screws in place, but I was not sure where the best placement would be. This shows the deluxe wood crate we build for each cap.

Cost: $470.25 php
(10% off for all needed info in his first e-mail plus
$335 worth of more copper used than in the quote)

From: "Ron Harneck" <rharneck@mydoitbest.c*m>
Subject: RE: Copper Hemisphere Roof Cap
Date: Sat, 25 Aug 2007

Good Morning David,

Installation hasn’t happened yet. We still have the copper dome here in the yard, with several other items that they need to finish the project. Have been waiting for the contractor to call for the delivery. Apparently he is busy on another job.

After the project is complete, I plan on going to see the finished work, will take some pictures and forward to you.

We opened the crate when it arrived, all curious to see this piece of art, we are impressed. Even the crate is impressive..... Great Job!!

Ron