Custom Copper Chimney Caps Page #2
'The Early Years of CBD'
(before I started using hardwood in the base/skirt)
(3/06 to 11/06)

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Below is a few more examples of custom copper chimney caps I've made; placing primary focus on a strong design w/as few seams as possible. There's also links to see more photos and details w/price breakdown of the parts used for most projects.

Note: We do not intend to be misleading with prices listed on these web pages for chimney caps made prior to to 2006, but with metal and fuel prices having doubled since then we have needed to compensate as well. So keep in mind how the prices listed may not reflect the current cost. They are here as a guide to see what these cost at that time.

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Matovich's Pair of  20oz Copper Chimney Caps
& lighted Cupola

Setauket, New York (10/11 - 11/30/06)

I made this a set of 2 chimney caps and a matching lighted cupola that are designed after our Tuscan arch style. These were for Scott Matovich in Setauket, New York, who had been patiently waiting around 6 months for me to begin his project. I shared 150 of these digital photos during the construction process with Scott through e-mail. I doubt there are any other sheet metal shops who would do that.

The larger unit has a 64" x 36.25" base with a roof that is 73.5" x 45.5". These have a 10/12 pitch hipped roof design to match their house roof, along with a thick stainless steel screening set back behind columns. We also included a custom angle cut wood frame for the larger chimney cap to rest on, with the stainless steel mounting hardware, so it is secure, yet removable for cleaning or other maintenance.

w/Matching Cupola and Built-in Lights

This is a matching cupola that is just a couple inches smaller than the small chimney cap shown above, but still taller with the taller base to sit on the roof. I had to do something a bit different with working out a soft glow light inside and rig up the security flood light in the base.

Total cost for this 3 unit project: $8,500 w/crates
($1,528.40 savings)
The client handled shipping costs through his account

To see all 84 photos of this construction and read more details:
http://copper-by-design.com/cc/cp/Matovich.htm
Installation photos added 3/07

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Fultz's 20oz Copper Chimney Cap
Richmond, Virginia  (9/06)

This chimney cap was designed by our client named Chris Fultz in Richmond, Virginia. He sent us a diagram he had made. It is great to get clients so involved in the creation process. I can recreate most anything a client can diagram. My primary goal is to provide what our clients want. Not what I want them to have.

Cost: $1,940 w/crate & shipping
to a residence with hydraulic lift-gate service

To see all 15 photos of this construction and read more details:
http://copper-by-design.com/cc/cp/Fultz.htm

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LEA Construction's Pair of 20oz Copper Chimney Cap
Brookings, Oregon (7/06)

This pair of chimney caps were designed for our client named Matt Eastaff of LEA Construction in Brookings, Oregon. These have a 4/12 pitch hipped roof design. The base is designed to wrap under the edge of the concrete slab that is over their chimneys and extends out past the rock facing. We include the stainless steel nuts and bolts to bolt the corners together, so it is secure, yet removable for chimney cleaning. The base rim here is 80"long and 48" wide, There is a 4" tall side on this lower rim of the base. The frame that supports the roof over the base if 10" tall with 6" tall vent openings that are 23" wide.

Total Cost: $3,410.80 without crates or delivery

To see all 8 photos of this construction and read more details:
http://copper-by-design.com/cc/cp/Eastaff.htm

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The Kensington 28 Unit 20oz Copper Chimney Caps Project
Sunnyvale, California (3/06 - 6/06)

We were contracted to build 28 copper chimney cap/shrouds with 18 gauge stainless steel screens to cover these typical small caps on an apartment complex in Sunnyvale California.

This chimney shroud project was designed by RSS Architecture. They first had a wood proto-type made with just the 4 side walls and installed to see how it would look from the ground. Then they had a non-functional galvanized steel shroud built for 1/3 the cost we charged for these copper units. Our's was a much better deal considering the copper costs over 6 times as much as steel, not to mention our improved design required about twice as much sheet metal. So if we had made them the same way, they would have only cost $750 each for copper, which if built well will last over a century.

After reviewing their design I offered several improvements. We offered some modifications to improve it's functionality and looks with adding a sealed roof over the top and 3" deep set inner walls for the side screened vents to add strength visually as well as structurally. It took several diagram revisions to get the final design locked down over the coarse of a couple months.

The right photo shows the same unit after only 3 months after installation, having turned this satin brown already.

They are 46.5" wide and 37.5" high. Several inches larger than the earlier proto-type they had built in steel. There is also a tapered pan built inside to shed rain that might blow in through the screened vents.  We offered to build one unit and ship it separately for installation before we continue building the rest of these units to make sure there was no need for design alterations. No alterations were needed.

Total cost: $45,279.20  delivered personally
26 at $1,531.11 ea. + 2 larger double flue units
They got the lowest cost per square foot of copper needed that we have given in several years. We shipped the first unit to them for inspection and fitting before proceeding on the other 27 units.

To see all 138 photos of this 28 unit project and read more details:
http://copper-by-design.com/cc/cp/Kensington.htm

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Trainor's 20oz Copper Chimney Cap
Fairhope, Alabama (2/06)

This chimney cap is for a client named Teresa S. Trainor in Fairhope, Alabama. It has a 6/12 pitch hipped roof made for it. The base is 71.5" x 44". There is a pan built inside to shed rain that might blow inside under the roof. The cap was co-designed by us and the client. It took several diagram revisions to get the final design locked down.

As you see in the photos above I recreated this diagram with great accuracy and detail. I weighed this to see what was the actual amount of copper used in this fabrication; and without the wood frame it weighed 182.5lb. Which divided by 1.25 equals 145.6 square feet of 20oz copper used in this chimney cap. We multiply this by our base rate of $25 which totaled $3,640 + $300 for the large wooden frame base. We spent another $65 on the engraved plaque she had requested be applied to the cap.

 There was a ceiling on the price of $4k, but we still wound up using a good deal more copper in this chimney cap than we had estimated.  So the building of the wood crate and the $300 shipping charge was pretty much free of charge to the customer. We worked on this for over 3 weeks and they saved about $1,000 on this.

Cost: $4,000 w/crate & shipping
to a residence with hydraulic lift-gate service

To see all 71 photos of this project and read more details:
http://copper-by-design.com/cc/cp/Trainor.htm  

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Takhar's 20oz, 24oz, & 32oz Copper Double Walled Shroud,
Flue-pipe, Roof Flashing, & Screened Chimney Cap
Bemidji, Minnesota (3/06)

This fireplace hood was a collaborative design with our client named Harry Takhar in Bemidji, Minnesota to keep with a square looking design. It has a 7.5/12 pitch hipped double layer hood design. The base rim here is 4' 9" wide square, but the outer shell is 5' 2.5" wide. There is a 4" tall rim on the outer shell. The two layers are spaced 2.5" apart with the internal bracing you see mounted on the liner and later attached to the outer shell. It was made to be mounted over an outdoor fireplace that is under a breezeway roof between a pair of enclosed gazebos.

You can see here the white vinyl covered outer shell that is a thicker 24oz copper from a different supplier than we buy most of our copper from. Once assembled it was structurally solid feeling and did not seem to have any flex to it. It is resting on a shipping crate waiting to be picked up by the trucking company Roadrunner/Dawes, which contains a large turret roof cap.

145 lb - Cost: $2,900

Here is the square 8' 10" tall double walled flue pipe he requested we make for the hood to deliver the exhaust safely out through the roof. It weighs just over 100#, which translates to 80.4 square feet of the 20oz copper sheet metal we use. It took 3 sheets that are 3'x 10' of copper to make this one flue pipe.

101 lb - Cost: $2,020


We also made this roof flange and small chimney cap shown below to go over that flue pipe. The flange base was made out of a 3' x 3' thicker sheet of 32oz copper and weighed 24# with the 24oz copper collar seen in white. The 20oz copper chimney cap has a 16 gauge stainless steel screen and weighed 24#.

48 lb - Cost: $960

Here is the 37.5" wide fireplace cover lid we got for him and attached this brass handle onto. The second photo is a close-up of a stainless steel eye with a 4 gauge copper wire wrapped over it. To just wrap 2" of the end that wire took 3' of a smaller diameter 14 gauge copper wire. We shipped a spool of 100' of the thicker copper wire, and 20 sets of the thinner wrap wire with this example piece. It is to support the hood under the roof beams. We also sent a dozen 1/4" thick SS eye hooks to connect the copper support wire to the beams ahead.

Cost: $375 & $326

Total Cost for this 6 part assembly: $7,831 w/crate & shipping
to a residence with hydraulic lift-gate service

To see all 40 photos and read more details of it's construction:
http://copper-by-design.com/cc/cp/Takhar.htm

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Back to Chimney Caps page 1
'My first chimney caps prior to CBD'

Or on to Chimney Caps page 3
'Introduction of hardwood in base/skirt'

 

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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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