The Bucchioni Custom Hinged Copper Chimney Cap Details & Photo Page

(attachment bases ISD: 23.75" X 38" & 26" X 48.25")

Woodbury, Connecticut (6-7 / 2012)
Updated 12 / 2012

Company
Profile
Roof Caps You are here Chimney
Caps
Scuppers Gutters Shipping

Contact Info


.

Working Out this Design (4/4 to 6/8/2012):

This order for a pair of copper chimney caps was for Charles Bucchioni in Woodbury, Connecticut. After finding my web site he had contacted me on 4/4/2012, and by the 15th he had laid down $2k for a deposit to get this project fit in my cue, while we took the next 2 months to casually work out the details w/o pressure to make any hasty decisions.

A Grecian style copper chimney cap for my client McLaughlin in Staten Island, New York

The Greek style columns were patterned after a chimney cap I made back in late 2007 for a client named McLaughlin in Staten Island, New York (shown above left). The differences were how he did not want the SS spark arrest screen, there's a squared off trim over the side of the base/skirt, middle of the columns, and on the rim of the roof, but the most amazing difference was how he wanted me to make the upper roof hinged from the base, so it could be opened when it may need the flues cleaned w/o having to remove these chimney caps. Something I had not done before on any chimney cap, but I think it turned out and looks very good. Although, this set took twice as long to build than I had predicted.

It was very trick to design this to be simple enough to use and sturdy. I used 4" solid brass door hinges and a stainless steel cable to keep it from opening too wide. There's a set of 2 SS lock pins on each of the columns on the other side from the hinges to keep it shut when not open. They are strung on the SS cable, so they will not get dropped and lost.

I designed the roof line to match their house roof line with a hipped 6/12 pitch, so this will look more like what the architect might have designed for this house. The client approved this design and has been very pleased with the results.

From: "Bucchioni, Charles" <Charles.Bucchioni@ge.c*m>
Subject: RE: Custom no-rust copper sheet metal chimney caps fabrication
Date: Fri, 13 Jul 2012


David,
They really look great – that last picture with the roof on was like “wow”. The construction of the caps is extremely impressive, they look like they will withstand a category 5 hurricane. I can’t wait to see what they are going to look like on my house.

Chuck

At 12:45 PM 11/12/2012, you wrote:

David,
Hope all is well and business is good. Wanted to shoot you a quick e-mail message and let you know how pleased I am with the chimney caps. I’m sure you’ve heard about hurricane Sandy that affected the north East Coast. I’m happy to let you know that both chimney caps made it through the storm without an issue. Attached are a couple of pictures, 1st is a giant tree limb hung up in the electrical wires across the street from my house, the other is the top of a tree in my back yard that the wind snapped like a twig and the other is where the top of the tree came from. Yesterday I cleaned one of the chimneys, took about the time and was a way less aggravating. The “pins” were a much better idea than a thumb screws.

Still a very satisfied customer,
Chuck

Drafting Out & Forming the Base/Skirt (6/8/2012):

Here's the 1X6 Ipe hardwood support frame I need to build inside the copper base that helps anchor this down in high wind storms. Each board was cut on all 4 sides at an angle. The top and bottom were cut on my table saw at a 26.5 degree angle and the ends were cut at a 45 degree angle to miter them together. They will be positioned down low where it should not suffer heat from the chimney and shielded from the elements.

Above left you can see the inside of the base/skirt for the chimney cap cut out and shaped  with the wood being pressed down into the frame while the expanding Gorilla Glue sets. Then it is ready to be assembled into this base/skirt seen below right. The inside of the hardwood is treated with pure tung oil to keep it from moisture.

We even added a small board inside the square trim so it is not just hollow.

From: "Bucchioni, Charles" <Charles.Bucchioni@ge.c*m>
Subject: RE: Custom no-rust copper sheet metal chimney caps fabrication
Date: Wed, 13 Jun 2012

David,
I got them all. I never realized how the anticipation level increases seeing these things getting formed and assembled. They look great.

Chuck

Forming Ornate Columns w/Integrated Hinges & Latches (6/16/2012):

It took several days just to build this set of 8 lower pieces of the columns and add the decorative copper pipe trim work before we could attach them to the bases.

Each corner column required a pipe that was about 24" long for the 6" wide block. It took the majority of two 10' pipes for these chimney caps. The column are then attached to the base with SS screws and many rivets from underneath, so they are not seen, yet plenty sturdy.

We used a less expensive aluminum sheet metal to form the practice piece for the columns to make sure they would work out and look right before forming these in copper. Steel would be cheaper, but aluminum is easier to work with, and we have plenty of gutter coil left over. Integrating the 4" door hinges was tricky to make sure they were strong and as hidden as they could be.

It took several more days to work this out. We used a thicker 32oz copper for over the pipe trim for added strength. The brass hinges are soldered and bolted down with SS bolts, so they cannot vibrate loose.

From: "Bucchioni, Charles" <Charles.Bucchioni@ge.c*m>
Subject: RE: Custom no-rust copper sheet metal chimney caps fabrication
Date: Tue, 26 Jun 2012

David,
Wow, they look great. Impressive for sure, putting the copper shield over the hinges really makes them look excellent. Looks like you screwed the hinges in and also laid down a bead on them? They really look good, much better than I thought they would.
On my final payment, did you need me to send that now or wait until the final weight? Or I can send another installment and then a final once they are done and you have the weight. Either way is fine with me, just let me know.

Chuck

Building the Arches & Eaves (7/2/2012):

This shows the arched column section just after the sheet of copper is bent. There is a good deal of math and geometry involved here, so it's all in the right proportions. The first one did not go together right and had to be rebuilt from scratch with modifications.

We were able to make these from just 2 separate sheets of copper for a strong structure and a clean look with few seams, but there's another 20 pieces to go in before we can build the roof trusses.

Above right shows the 4 arch liners formed for this 1 chimney cap arch section. These are 8" wide to be an inch wider than the 6" columns on each side. After lots of test fitting and adjustments they were finally ready to be attached to the columns. 

From: "Bucchioni, Charles" <Charles.Bucchioni@ge.c*m>
Subject: RE: Custom no-rust copper sheet metal chimney caps fabrication
Date: Wed, 4 Jul 2012


David,
I was wondering what was up, thought you may have taken a break for the 4th. Fully understand the finger prints and not worried at all. They look great!! Can’t wait to see what they are going to look like on my house.
Thanks for the pictures and on another note I’ve been showing the pictures to the general contractor who is going to be installing them as he’s working on other things that need tidying up on my house, he requested I send him your contact information. Hopefully it will generate more business.

Chuck

Read reviews of Dmr GuttersFrom: "Bucchioni, Charles A" <Charles.Bucchioni@ge.c*m>
Date: Thu, 25 Nov 2012
Subject: Hurricane Sandy


I very rarely write positive reviews, its much easier to trash someone. I was searching the internet for chimney caps and by accident stumbled across Copper-By-Designs web site. Thankfully I contacted them. This by far is a 1st class operation so much so that I do not believe they have any competition. If you are looking for anything made out of copper there is no other place to go. They will assist you from initial design through installation. Their design knowledge is well above average, craftsmanship outstanding and communication throughout the project excellent. You will be hard pressed to find anyone better.

I live in the Northeast, we just got hit by super storm Sandy. Wind gusts measured in excess of 90mph. Hundreds of thousands of trees were knocked down. Branches flew through the air like arrows. The chimney caps produced by Copper-By-Design came through this disaster unscathed. A real life testament to the quality, design characteristics and installation methodology. Contact them, you wont be disappointed.

Still a very satisfied customer,
Chuck

Building the Roof Trusses and SS Cabling (7/9/2012):

We've already been working on these for over a month now and we have yet to start on the roof, but first there is the sets of roof support braces to make and attach with SS screws and copper rivets. This took over 50' of roof substructure bracing, which took 18.75 sq' of copper sheet metal to form.

I believe this is a very important detail that is not done by most any other sheet metal shop from what I've seen. I do what I can to prepare for the worst case weather these clients are likely to encounter.

I decided this will need the roof section sealed off entirely, so birds cannot nest up inside the roof.

Adding Up the Final Invoice from the Weights (7/13/2012):

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

.

Click in this photo to go back to Chimney Caps main info page

.


 

 

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

 

Back to homepage
Homepage

Site Map

.

Company
Profile
Roof Caps You are here Chimney
Caps
Scuppers Gutters Shipping

Contact Info
.

.

.

.

.

.

..

.

.

.

.

 copper-by-design.com