Custom Copper Chimney Cap Page #5

(1/12 to 4/15)

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Below are a few more examples of custom copper sheet metal chimney caps that I've made; placing primary focus on strong design w/as few seams as possible. There is also a link to see more photos and descriptions w/prices they had paid; to help give you ideas of what to request a personalized quote for.

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Spurgeon Chimney Flue & Cap
Banks, Oregon (4/15)

This was for over their fancy clay fireplace in their new house w/the weather-head positioned 8' 8" above this roof where the SS flue pipe exits the roof.

 

Cost Breakdown:

172# final weight for all 3 pieces
- 5.8 SS screen weight
= 166.2# of copper weight
X $25 per #
= $4,155 for the copper work
+ $160 for 8 sq' of SS spark arrest screen
+ $510 for delivery & installation help 2 stories up
= $4,825 grand total delivered and installation help

Here is a link to see all 65 photos of this project fabrication and installation:
https://www.facebook.com/media/set/?set=a.915601431795361.1073741829.130251686997010&type=1&l=6242304085

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LoVullo a pair of Dual Tower Chimney Caps
Grand Island, New York (1-2/15)



These were also made for their New York house they were in the process of building. We were also contracted to build one more chimney cap just like this for the same house that had no flue. Along with the 2 larger chimney caps listed below, 8 fancy scuppers, 8 Leaf-catchers, 2 turret roof caps w/finials and another chimney cap for their Florida home back patio pizza oven. These are nearly 7' tall.

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Cost Breakdown per set:

257.4# final weight
- 40.4# wood
- 6.4 SS screen weight
= 210.6# of copper weight
X 0.8
= 168.48 sq' of 20oz copper in this
X $35 per sq'
= $5,896.80 for the copper work
+ $306.30 for 20.42 ln' of hardwood in the base
+ $125 for 6.25 sq' of SS spark arrest screen
+ $650 for custom shipping crate
+ $850 for truck freight
= $7,828.10 total for one set of towers w/base
X2
= $15,6569.20 total for both delivered

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LoVullo a pair of 10 arch Tuscany style Chimney Cap
Grand Island, New York (9-12/14)

Also, for the LoVullo's new house in NY we made a pair of Tuscany style double & triple arch per side, double tier base, 6/12 hipped roof w/internal pans.



Cost: $10,869.40 each delivered to Grand Island, New York
Chimney cap final weight 370# each
(base ISD: 67.75" X 92.75", or 43.6 sq')


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Cost Breakdown per unit:

370# final weight
- 53.4# wood
- 20.4 SS screen weight
= 296.2# of copper weight
X 0.8
= 236.96 sq'
X $35 per sq'
= $8,293.60 for the copper work
+ $404.40 for 26.96 ln' of hardwood in the base
+ $653.40 for 32.67 sq' of SS screen
+ $750 for custom shipping crate
+ $768 for truck freight
= $10,869.40 total for one
X 2
= $21,738.80 total for both delivered

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Goodwin a pair of Greek style Chimney Caps
Point Pleasant, New Jersey (10/14)

For the Goodwin house in NJ we made a pair of Tuscany double & triple arch style, double tier base, 6/12 hipped roof w/internal pan



Cost: $10,869.40 each delivered to Grand Island, New York
Chimney cap final weight 370#
(base ISD: 67.75" X 92.75", or 43.6 sq')



Cost Breakdown:

Larger chimney cap:
232.5# total weight
- 41.6# wood weight
- 11.4# SS screen weight
= 179.5# copper weight
X 0.8
= 143.6 sq' of 20oz copper sheet metal
X $30
= 4,308 total for the copper (considerably less than the $6,500 I had originally estimated)

Smaller chimney cap:
214.5#
- 39.4# wood weight
- 10.6# SS screen weight
= 164.5# copper weight
X 0.8
= 131.6 sq' of 20oz copper sheet metal
X $30
= 3,948 copper for this copper
+ 4,308 copper for the copper of the larger chimney cap listed above
+ $760.00 for 38 sq' - stainless steel screen x $20(down by $76)
+ $586.20 for 39.08' - 5/4X6 ipe hardwood frame inside the base skirt x $15
= $9,602.20 sub total w/o delivery
+ $800 for 2 sturdy large wood crates
+ $975 truck freight charge for residential delivery w/hydraulic lift-gate service
= $11,377.20 total for both delivered

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LoVullo Pizza Oven Chimney Caps
Tierra Verde, Florida (7 / 14)

This was for their Florida home. We are also contracted to build another 4 larger chimney caps for their Buffalo, New York house, along with 8 fancy scuppers, and 2 turret roof caps w/finials.

Cost Breakdown:
Chimney Cap w/Weathervane:
109# final weight
79.2# copper weight
$2,376 for 79.2# of copper x $30
+ $200 for a water tight weathervane support pipe built into the chimney cap roof
+ $160 for 8 sq' of stainless steel screen x $20
+ $134.52 for 11.21' of 1X6 ipe hardwood frame inside the base skirt x $12
+ $380 for a 955P - 23" wide wing span Eagle style weathervane w/custom made copper fish in mouth addition
+ $250 for a sturdy wood crate
+ $350 truck freight charge for residential delivery w/hydraulic lift-gate service
= $3,850.52 grand total

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Aumann Chimney Flue Cap
N. W. Portland, Oregon (8/14)

 



This was for over their fancy clay flue liner that has a natural gas exhaust, so I needed to also build in this a separate fresh are return under the main exhaust weather-head.
Cost: $1,019
installed
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Davis - Set of 3 Chimney Caps
Bedford, New York (12/13 & 6-7/14)

These were custom made for Scott and Antonia Davis in Bedford, New York for their outdoor fireplace first. Then a few months later contracted to make larger rectangular caps for their home as well.




Cost for all 3 chimney caps: $14,589.67 delivered
attachment base ISD:
33.5" X 36.25", or 8.4 sq'
40" X 65.25",  or 18.1 sq'
& 40" X 85", or 23.6 sq'

Smaller Chimney Cap:
86.4#
Final weight
- 20# wood and SS screen weight
= 66.4# of copper weight
X 0.8
= 53.12 sq' (down from the 68 sq' I had quoted)
X $35 per sq'
=
$1,859.20 for 53.12 sq' of copper work
+ $149.04 for 12.42 ln' of hardwood in the base
+ $124.40 for 6.22 sq' of SS spark arrest screen
+ $175 for custom shipping crate
+ $275 for truck freight
= $2,582.64 total delivered separately

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Large Chimney Cap:
168# Final weighs
- 30.6# wood weight of
- 6.4# SS screen weight
= 131# of copper weight
X 0.8
= 104.8 sq' of copper

X $35 per sq'
= $3,668 for 104.8 sq' of copper work
+ $207.48 for 17.29 ln' of hardwood in the base
+ $231.20 for 11.56 sq' of SS spark arrest screen
+ $325 for custom shipping crate
+ $525 for truck freight w/residential lift gate
= $4,956.68 total delivered for this first unit

Larger Chimney Cap:
251.9# final weight
- 46.4# wood weight
- 15# SS screen weight
= 190.5# of copper weight
X 0.8
= 152.4 sq' of copper
X $35 per sq'
= $5,334 for 152.4 sq' of copper work
+ $318.15 for 21.21 ln' of hardwood in the base
+ $373.20 for 18.66 sq' of SS spark arrest screen
+ $375 for custom shipping crate
+ $650 for truck freight w/residential lift gate
= $7,050.35 total delivered for this first unit

= $14,589.67 grand total for all 3 chimney caps
w/crate & freight
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Solari Pair of Chimney Caps
South of Salem, Oregon (11/13)

 

Cost: $3,212.55 undelivered(client picked them us, as you see here)
attachment base ISD: 21.25" X 25.5" & 25.25" X 40.75", or 3.76 sq' & 7.22 sq'

Cost Breakdown:

Smaller Cap w/roof liner:
62.2# total weight
- 14.1# wood weight
- 4.2# SS screen weight
= 43.9# total copper weight
X 0.8
= 35.12 sq' of 20oz copper in this
X $30 per sq'
= $1,053.60 for the copper
+ $110.80 for 5.54 sq' SS screen
+ $126.60 for 8.44 ln' of wood
= $1,291 subtotal

Larger Cap w/roof liner:
92.8# total weight
- 20.6# wood weight
- 6# SS screen weight
= 66.2# total copper weight
X 0.8
= 52.96 sq' of 20oz copper in this
X $30 per sq'
= $1,588.80 for the copper
+ $157.40 for 7.87 sq' SS screen
+ $175.35 for 11.69 ln' of wood
= $1,921.55 total for the larger chimney cap

+ $1,291 for the smaller chimney cap

= $3,212.55 grand total for both chimney caps
w/o crate or freight
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Rossi Chimney Cap, Mantle, and Fire Screen
Palos Verdes Estates, California (4/13)

36" wide cedar mantle covered in 32oz copper w/oversized rivets

 

Cost: $5,010.25 delivered
(attachment base ISD: 31.75" X 31.75", or 7 sq'.
Fire-screen is 48" wide X 39" tall in the center)

 

Cost Breakdown:

Mantle final weight is 33.6# - 13.8# wood weight = 19.8#
$156 for 19.5 ln' of 6" wood X $8
+ $396 for the 32oz copper covering this 19.8# X 20
+ $116 for 58 large rivets X $2
= $668 sub-total (down from $750 quoted)

Chimney Cap final weight is 105.2#
$2,060.80 for 73.6# of copper X $28
+ $464 for 232 large copper rivets X $2
+ $142.40 for 7.12 sq' of SS spark arrest screen X $20
+ $175.05 for 11.67 ln' of 5/4 X 6 hardwood in the base/skirt X $15
= $2,842.25 sub-total

Fire Screen: $600 as quoted

Freight costs:
$400 for a 44" X 48" X 53" custom crate with packing for all 3 pieces
+ $218.25 truck freight w/liftgate residential service
= $618.25 sub-total

To see all 56 fabrication w/installation photos and read more about this project:
http://copper-by-design.com/cc/cp/Rossi.htm

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Lulich Chimney Cap
First double arch Tuscany style chimney cap w/6/12 hipped roof, & SS spark arrest screen
S. W. Portland, Oregon (12/12)

 

Cost: $3,577.70 delivered. Final weight 133.8#
(attachment base ISD: 20-7/8" X 56-3/8", or 7.9 sq')
Saved $122.30 - for less material used than quoted

 

The wood weight was 28.4# + 8.8# for the SS screen = 95.8# copper weight

$2,615.20 for 95.8 # total 20oz & 24oz copper X $27.30 #
+
$258.80 for 12.94 sq' - stainless steel screen X $20
+ $203.70 for 13.58 ln' - 5/4X6 ipe hardwood frame inside the base skirt x $15
+ $250 for crane service (his minimum charge)
+
$200 for our part in the delivery and installation
+
$50 for 4.5" wide round plaque

$3,577.70 total delivered and installed

To see all 70 fabrication w/installation photos and read more about this project:
http://copper-by-design.com/cc/cp/Lulich.htm

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Fennern Chimney Cap
basic chimney cap w/16/12 gable end roof, & SS spark arrest screen
Newberg, Oregon (11/12)

 

Cost: $3,031.28 delivered. Final weight 133# w/o weathervane
(attachment base ISD: 25-7/8" X 37-3/4", or 6.82 sq')
Saved $470.67 - for more material used than quoted

 

The wood weight was 28.4# + 8.8# for the SS screen = 95.8# copper weight X $20# = $1,916

$1,916 for 76.64 total square feet of 20oz & 24oz copper X $25
+
$146.80 for 7.34 sq' - stainless steel screen X $20
+ $169.35 for 11.29 ln' - 5/4X6 ipe hardwood frame inside the base skirt x $15
+ $125 for weathervane support pipe built into the roof
+
$170 for 24" tall Segmented Globe
+
$170 for 18" long flag weathervane
+
$400 to buff & lacquer all of the out side of this project

$3,502.15 sub total
$3,031.48 total delivered and installed

To see all 27 fabrication w/installation photos and read more about this project:
http://copper-by-design.com/cc/cp/Fennern.htm

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Muenster Chimney Cap
basic chimney cap w/6/12 hipped roof, & spark arrest screen
Sioux Falls, South Dakota (8/12)

 


Cost: $4,150 delivered. Final weight 174.8# w/o crate, 320# w/crate
(attachment base ISD: 25.25" X 96", or 16.83 sq')
Saved $201.50 - less than quoted

The wood weight was 45.4# + 20.4# for the SS screen = 65.8#.
This means the copper weight alone is 109# X 0.8 = 87.2 sq' of 20oz copper left in this project
X $30 = $2,616, so we were right on target from the original quote of $2,647.50

$2,616 for 87.2 total square feet of copper X $30
+
$342 for 17.1 sq' - stainless steel screen X $20
+ $315 for 21 ln' - 5/4X6 ipe hardwood frame inside the base skirt x $15
+ $450 for a sturdy large wood crate
+
$350 truck freight charge for residential delivery w/hydraulic lift-gate service

$4,073 total delivered

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Bucchioni Chimney Caps
Pair of Greek arch style w/6/12 hipped roof, which hinges open from base
Woodbury, Conneticut (7/12)

Attachment bases ISD: 23.75" X 38" & 26" X 48.25"

The weights and cost breakdown of these pieces are as follows.

117.8# - for the smaller unit
138.8# - for the larger unit
= 256.6#
- 46# wood weight
= 210.6#
X 0.8
= 168.48 sq' of 20oz copper used in all for both.

X $30 sq' rate
= $5,054.40 - for copper
+ $236.70 - for 23.67' - 1X6 ipe hardwood frame inside the base skirt x $10
+ $280 - for 4 brass door hinges, 40 SS bolts, 80 SS nuts, 50' SS cables, and 8 SS lock pins
+ $400 for a strong large 38" X 5' X 4.5' tall custom wood crate for both caps
+ $500 shipping charge to your home w/hydraulic lift-gate service
= $6,471.10 total for both delivered.
- $4,000 paid
= $2,471.10 balance

To see all 36 fabrication photos and read more about this project:
http://copper-by-design.com/cc/cp/Bucchioni.htm

Also, you can see a of this chimney cap open from the video the client was nice enough to shoot and share with us:

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Finn Chimney Cap
Simplified Tuscany arch style w/6/12 hipped roof w/Client's Company Logo
Vienna, Virginia (2/12)


Cost: $5,500 delivered to Vienna, Virginia
(attachment base 33" X 80" ISD, or 18.33 sq')

The weight and cost breakdown was as follows:
233.5# - total weight
- 42.2# - wood in the base
- 26.8# - SS screen
= 164.5# - copper weight
X $24# rate
= $3,948 for the copper
+ $660 - 33 sq' of SS screen
+ $292.50 - for 19.5 ln' of 5/5X6 hardwood inside the base
+ $500 - custom wood crate
+ $650 - truck freight to VA residential delivery
= $6,050.50 grand total - less quoted ceiling cost for this project

To see all 16 fabrication photos and read more about this project:
http://copper-by-design.com/cc/cp/Finn.htm

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Sarkinen's Concave Hipped Roof Chimney Cap w/weathervane mount built in
St. Michael, Minnesota (1/12)

After building a mantle piece over a year prior I was contracted to make this stylish concave hipped roof design chimney cap for Chris & Christine Sarkinen in St. Michael, Minnesota to to cover natural irregular stone outdoor fireplace. This curved roof line has not internal support, so we decided to use a thicker 32oz copper on top.

It also needed to have a weathervane support pipe built into the roof for this stork style weathervane they got from a different Coppersmith who specializes in this sort of custom hammered copper work.

Although, we felt there were a few problems with the design of this weathervane; as it seems rather confused. My Wife and I looked up over a hundred images from cartoons to photos of actual storks in flight to see what was bothering us about this design:
(a) The most noticeable is the small torso they made. It should have been at least 2 to 3 times larger in proportion to the neck and head.
(b) I understand making a silhouette WV, but if you are going to make it 3-D, then it should be 3-D. This has a slender 3-D torso, but that's where it ends.
(c) The neck should be curved more with the head a couple inches higher.
(d) The legs should be hanging down more to show the thighs that seem to be missing.
(e) From what I can see they cannot bring their wings straight up like that w/o breaking their wings or at least hurting themselves. Maybe half that high at a 45 degree angle.
(f) The wings are convex, where they should be concave. I know they may have been thinking they are on a downward stroke, but that still is not a valid argument, since that is not a truism.
(g) I tested it in the wind outside, but this design will not point in the direction the wind is coming from very well. It does not have more tail than nose. The baby bag in front counter the drag of the wings that are behind the center pole.
(h) The balance is off with it being nose heavy. I am pretty sure they should be made balanced to the center shaft, but if they are not they should be tail heavy. Not nose heavy.

I believe I could have done better for less, but what is done is done.

Cost: $2,722.17 delivered
 to St. Michael, Minnesota

The weight and cost breakdown was as follows:
78.2# - total weight
- 14# - wood in the base
- 4.1# - SS screen
= 60.1# - copper weight
X $25# rate (special discount for unique design)
= $1,502.50 for the copper sheet metal
+ $270 for the 180 decorative industrial rivets
+ $116.67 - 5.83 sq' of SS screen
+ $108 - for 9 ln' of 1x6 hardwood inside the base
+ $125 - weathervane support pipe
+ $250 - custom wood crate
+ $350 - truck freight w/residential delivery
= $2,722.17 grand total

As stated above the weathervane was supplied by a different vendor. We gave them a discounted cost for having us make this unique design we had not done before.

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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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