CBD's Peabody Chimney Caps Page

This set of 2 copper chimney caps for Ed and Gloria Peabody in Westport, New York installed over their brick chimneys of their modest home. They first contacted me 12/11/09 and we swiftly worked out the details of this project through e-mails, and within a couple weeks they had sent in a 1/3 deposit to schedule this in.

The larger chimney is 51" long and the smaller on is 39.25. They both had the same width of 31.25". They originally wanted these built in just a simplistic low profile style like I had done for a former clients LEA Construction in order to save cost. Although, just before I had a chance to begin work on these; they mentioned concern about restrictions of exhaust flow and wanted to discuss design alternatives. Keeping in mind how they wanted to keep costs more reasonable I suggested a simplified version of my Tuscany arch style that has been so popular. Much like I had done for Mr. Reeves back in late 07.

Here's the 8 pieces of the base support frame I need to build in copper for this pair of chimney caps. This part is what hooks underneath to anchor them down in high wind storms on the concrete slab over their chimneys. I had to make these so the corners can open up to let the metal flex out over that slab and cups under it for attachment. The corners then will be fastened together with the pair of stainless steel bolts with washers and lock nuts on each corner.

This shows part of the columns without the arches between them. Each column is attached to the base with 12 to 13 rivets, but that's not what holds them in place the most.

These columns hold the sides of the stainless steel spark arrest screen in place with a channel formed to cup the edges of the SS screen. It also is held across the bottom edge with a channel formed in the base sections. These SS screens are not just loosely set in these channels. They are fastened in with hundreds of copper rivets, so they also become part of the structural integrity of these units. They are already much more rigid.

Then the eaves are made and attached over the corner columns and cup the top edges of these SS screens and riveted into place, which adds a lot more strength to these structures. I also added a few SS screws at the corners.

Then there's the roof support braces to make and attach with copper rivets. 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 know they may get a lot of snow there in New York, so these roof support braces are only about 8" apart for uncompromised strength.

Then after a couple weeks work on these they were finally ready for the copper roof skins to slide over these braces and cup under the eaves. It is very tricky to make this roof skin in just 2 pieces for a nearly seamless construction. They are still riveted down to the roof braces to help keep them from rattling in the wind.

This is the crate I built to carry them safely on their journey across the Country. The larger chimney cap is not resting on the smaller one. There is cross boards under to suspend it over the other cap. I also made a 1/4" thick plywood shield over the smaller cap's roof just incase something came loose, or just from bouncing on the roads.

The crate weighed almost as much as the contents. It is 40" wide X 60" long X 68" tall and weighed around 375# in all.

I got the separate weights as I worked on these while taking these digital photos to share with the clients most every night for their review as the progress continued:

Larger Chimney Cap:

30.4# - Base and Columns = 24.32 sq'
7.2# - SS screens = 12.06 sq' X $20 = $241.20
9.4# - Arches = 7.52 sq'
6.8# - End eaves = 5.44 sq'
7.6# - Long side eaves = 6.06 sq'
8# - Roof Support Braces = 6.4 sq'
30.4# - Roof Skin = 24.32 sq'
99.8# total weight
92.6# copper = 74.08 sq' X $25 = $1,852
$2,093.20 sub total

Smaller Chimney Cap:

26.8# - Base & Columns = 21.44 sq'
5.6# - SS screens = 9.53 sq' X $20 = $190.60
7.2# - Arches = 5.76 sq'
6.8# - End Eaves = 5.44 sq'
11.2# - Long Side Eaves & Roof Support Braces = 8.96 sq'
21.2# - Roof Skin = 6.4 sq'
78.8# total weight
73.2# copper = 58.56 sq' X $25 = $1,464
$1,654.60 sub total
$2,093.20 - larger cap
+ $1,654.60 - smaller cap
+ $450 - for the crate
+ $400 - for truck freight shipping to residential w/lift-gate service
= $4,597.80 Grand Total
- $2,820 paid
= $1,777.80 balance due before they shipped

These were the photos sent to us by the client showing the installation.

From: "Edward Peabody" <peabodye@westelcom.c*m>
Subject: Chimney Caps Installation
Date: Mon, 12 Apr 2010

We had the chimney caps installed today. The large one went great, and the other took some extra effort because the cement cap Had a curve on one side. Glad you sent the spare nut and bolt sets, because the guys dropped several pieces. We think they look terrific. Here are some of the photos I took. Thanks again for the great job.