Below are a few examples of chimney flashing kits I've made for clients across the Country.
In case you have not yet seen my other chimney flashing photo page:
http://copper-by-design.com/cc/cf.htm
http://copper-by-design.com/cc/Reflashing.doc

Clearly chimney flashing is the #1 most neglected area of a roof by even the most professional roofers I've seen when reroofing a house. It is very rare they will use just aluminum flashing, let alone copper, which saves them about as much as the cost of a burger by using steel, which will not last as long as just 25 year shingles. Most roofers I've seen will not even bother to replace that old flashing no matter how rusty it is.

That's where I come in.

I have actually reflashed hundreds of chimneys myself in this manner, so I have a pretty good understanding of what it takes to do the job right. These flashing kits I make have become a very popular item with my clients all over the Country, since no one else seems to be offering this sort of personalized service for small ticket items like these.

Heck, it's a great way to use up my smaller cut-off scraps of the 20oz copper sheet metal I have left over from larger custom copper projects I build, so I am able to sell these kits for just $15 to $20 a square foot + shipping, depending on the size and complexity. I can make these in painted aluminum parts as well, but in my experience it is not worth the moderate savings considering all the labor this sort of project takes. The cost of these kits are based on the final weight to determine exactly how much copper went into it, so your not paying for any cut-off waste or inflated quote at that rate. That's one heck of an honest deal that you're not likely to find elsewhere. It's also a detail you can double check when your kit arrives.

The pieces in these kits are labeled and numbered as to where they go and in what order they are to be installed. I also do my best to round off the sharp corners, so there's less chance of getting cut while handling these. They also come with copper nails, so all you should have to pick up locally is the mortar and some hand tools, as described in the 'doc' file above. The upper saddle is not required, but is highly recommended to divert the rain water and debris off to the sides of the chimney, as opposed to just a straight horizontal tray like you may have now.

What info do you need from me to make a good custom kit?
(a) Good clear photos. Fortunately most people now days have a digital camera and know how to send picture through e-mail. I've successfully worked with thousands of client this way over the last few years. Most of my clients have been not just out of State, but on the other side of the country.  It's important for me to see what your situation is up there, so I'll need some fairly close-up photos showing the sides of the chimney where it meets with the roof.

(b) The roof angle as well, so I can cut the counter-flashing at just the right angle, minimizing the copper you'll have to pay for and less cutting copper pieces there up on the roof. The roof angle is based on how far the roof drops for every 12" straight out. It's best to have a level to make sure the 12" is horizontal, then just how far straight down from the end. You can use a board laid flat on the roofing to get a better idea of the real slope of the roof, as shingles can be a bit lumpy.

(c) The measurements of the chimney at the point where it meets with the roof of course. These measurements should be as accurate as possible, so I can do as much cutting and bending for you as I can, so you will not have to do much customizing yourself up there up on your roof.

A little personal history:
I originally built a sheet metal shop in my basement to custom fabricate my own aluminum flashing and paid the 5X cost for roofers liability insurance for several years, but with no employees I could not do the volume of work it took to afford that expensive insurance. Over the last 2 decades my little sheet metal shop has grown and evolve to building many different custom aluminum, stainless steel, and now mostly copper rain management products that can be seen on this web site.

I use to be very intimidated by the high cost of copper even before it doubled in cost back in 2006, so I used a clay red prepainted aluminum flashing for chimneys, knowing it is a lot better than just the cheap steel that is normally used. I stopped using aluminum all together for chimney flashing around a decade ago. The cost difference between using a cheaper metal was not worth it. Especially considering the amount of labor this type of project requires.

 I've seen Masons charge $750 just to reflash a single flue chimney with only painted steel back in the mid 90s when copper was half what it cost these days. They saved a grand total of $40 by using steel in stead of using copper. If done with copper you should not need to redo it again the next time it is re-roofed. Or even the next several times. Aluminum would easily last several decades, but the paint would flake off over time and begin to look terrible, so it is not as reusable as copper. It would also crack more easily if the brutal roofer felt he had to bend it up to fit the step-flashing in under it as he re-roofs. Copper is much more malleable. Another advantage is how it will retard the growth of mildew and moss on the roofing below it.

There needs to be this 2 part flashing: the step-flashing is integrated with the roofing and sets up flush against the side of the chimney. Then the counter-flashing is mortared in between the bricks in horizontal lines only to overlap the step-flashing. This 2 part system allows for the movement that is caused with the expansion and contraction of these 2 very different types of structures, while maintaining this seal. Of course the bricks will expand with temperature changes differently than the wood structure of the house. Even 1/4" movement would be enough to rip open any other method used to seal the chimney to the roofing. This is not a new method by any stretch. It is a time tested technique used for centuries, and I have yet to see a better technique for this purpose.

Can You Make Us a Custom Copper Chimney Flashing Kits:
My base rate for custom work is $25 sq', but I've made up lots of these custom chimney flashing kits for clients across the Country for as little as $20 sq' of the same 20oz copper as indicated in the final weight plus shipping if you are not local. A single flue chimney flashing kit should not run more than $250 w/shipping. For a bit extra I can also build a custom cricket to match your roof angle with  or without wood support attached underneath (as shown below), in stead of just the normal horizontal tray that traps lots of debris:

Upper left side discharge chimney cricket

Below shows a duel sided discharge chimney saddle that is to replace the straight horizontal tray; like you may have now. I make it as seamless as possible and sealed with a cover piece over the splits soldered in place. I can also add a custom plywood support under the saddle for dent resistance. This sort of saddle is not required, but highly recommended.

Client installed chimney flashing