Decorative/Functional Custom Copper Sheet Metal Chimney Cap Fabrication Main Information/Navigation Page

Updated 8 / 17

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Back ground drawing courtesy of: The home of John and Dorothy Berrigan in Stone Harbor, NJ. Designed by Paul Kiss of Olivieri, Shousky Kiss, and built by D.L. Miner Construction

David Rich w/Tuscan style copper chimney cap for Cross in  Chester, New Jersey 
 David Rich standing in front of our most popular design: Tuscany arch style chimney cap

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 Quick Info Bookmarks:

Examples of Our Work w/Prices Info We'll Need Pricing
Intro: How CBD is different Shape Options Lead Time
Why Copper Sheet Metal? Shipping Orders Fasteners
Our Main Advantages Client Satisfaction References
Sheet Metal Thickness? Minimum Order UL Listing?

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Below are examples of custom sheet metal chimney caps built by CBD with 99.9% pure copper built with 20oz, 24oz, 32oz, and some 48oz thicknesses. The thickness is based on weight per square foot. We do not use the thinner 16oz copper, which is primarily used in most other shops willing to work with copper. Over the last decades CBD places focus on these details, not commonly done in other shops. Advantages you are not having to ask for with a CBD fabrication:

  1. Thicker copper than standard.

  2. A more 3 dimentional design for a better look, which also makes this a much sturdier construction.

  3. Weather tight w/o caulk or solder, because it would not even handle more than 450 degrees, or oven temperature. Not even suitable for a natural gas flue.

  4. More seamless design for a better looking and stronger fabrication with less visible rivets.

  5. Endoskeleton framework. As opposed to the common exoskeleton: standing seam design.

  6. 10X stronger 13ga flattened expanded high grade stainless steel spark screen, which adds a good deal of strength to these hollow structures.

  7. Easy yet sturdier attachment than you'll find elsewhere, including a set of custom lift boards roped together ready to use for the installation.

Value:
Keeping in mind anything is only as good as it's weakest link, so why use a life-time metal like copper if it is not built well to handle the elements for many decades. Perhaps a century even. Like with an investments in gold; copper is also a rock solid investment in a valuable metal not subject to inflation, like your savings account. Some Homeowners may see these as a bit pricy. Although, this same person would not scoff at a $5k+ upgrade for pimped out rims  and running boards on a new SUV purchase. Is this not just as valuable up there as the crowning jewel on your home?
(copper costing us 5X more than the aluminum of your wheel rims that were not hand made or a unique original design)

Clearly CBD is the best value for all with put into each project, which typicaly takes a couple weeks to produce. Unlike other speed-shops around.

Listed below I've provided more information here than you'll find on any other web site of this nature, so you can anonymously shop prices. Each photo links to a full screen image for a better look, or it links to a more detailed web page with more photos and descriptions of that project. Many with step-by-step photos. This helps you compare prices and give you ideas for a personalized quote w/o having contacted me, and possibly suffering through a high pressure sales scheme, as you find with most other web sites that do not list any prices.

There are several of our popular Tuscan arch style chimney caps shown below, which may looks the same, but they are each unique and have different size bases to give you a better idea of what it may cost for your home. The roof may be wider than the base, or numerous other details that are different to choose from. We do not offer a discounted cost for just copying a previous design. Custom deigns are our specialty, so don't me shy to ask us for something special. Our Clients placing faith in our ability is what has allowed CBD to offer such a wide variety of examples shown here.

You may also find our chimney flashing kits beneficial:
http://copper-by-design.com/cc/cf.htm#kits

Note: We do not intend to be misleading with prices listed on these web pages for projects made prior to to mid 2006; back when copper was 1/2 the cost it is now, so each project is clearly dated. As you may have heard; metal and fuel prices had doubled that year at the end of the first term of the Bush II eara. So keep in mind those prices listed were just what they had paid at that time.  You can go to our Latest News web page to read more on this subject.

Pictured below are chimney caps I've built in order of the latest - back
They are listed by the clients last name, instead of making up some cute name for each style

Just click on the photos below to see and read more about each project

The most important advantages of our service may not seen as much from the outside; how I do things a bit differently:

We use a stainless steel spark arrest screen that is a lot stronger than a copper screen would be, which also helps keep out critters from nesting up inside the chimney cap or flue. A rabid raccoon would not be able to claw or chew through this screen.

The spark arrest screen is usually deep set into the corner columns under the roof cover ledge. Not flush like other shops tend to make.

I don't build the roof with standing seams, or an exoskeleton like you see on most other chimney caps, yet we make it stronger and cleaner looking with an endoskeleton frame to resist the weight of snow loads or broken off branches in a wind storm.

Also, I make a base/skirt that comes down further at 5" for a much more stable hold with an ipe hardwood board inside for weight, strength, and far better threading for the SS screw tension than just a single layer of sheet metal could offer.

It has been a gradual process over the years to refine this process of how I design and build these to last and hold up under the elements, while being simple enough to remove for cleaning the flue when required. I will supply the stainless steel screws for attachment. These screws will not need to be driven into the brick or stone. Just apply pressure. Therefore making it secure in high winds, yet still removable decades later with less risk of the screw seizing to the frame.

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Latest Chimney Caps page #7


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Tulloch - (5/17)
Simplified Tuscany arch style, w/a patina

Cost: $4,406.70 shipped to Winston-Salem, North Carolina
Chimney cap final weight 136#
(base ISD: 36" X 55.5", or 13,88 sq')
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Shelton - (4/17)
Tuscany arch style, w/a convex arched roof cover

Cost: $6,185.91 installed in Salem, Oregon
Chimney cap final weight 238#
(base ISD: 36.25" X 71.75", or 18 sq')
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Mughal - (3/17)
Tuscany 6 arch style, w/double tier base, & 6/12 hipped roof

Cost: $14,366.51 installed in Beaverton, Oregon
Larger chimney cap final weight 219.6#
(base ISD: 36.5" X 69.25", or 17.55 sq')
Smaller chimney cap final weight 192.6#
(base ISD: 33" X 63", or 14.44 sq')
Cupola final weight 199.8#
(base ISD: 40" sq, or 11.11 sq')

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Chimney Caps page #6

'The More Adventurous Years'

O'Brien  - (1/17)
A small flue liner fit chimney cap

Cost: $500 - 12.25" X 16.35" ISD
(without a crate or freight and Client supplied the hardwood)
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Helffrich - (1/16)
A concave hip roof shape w/weathervane/finial mount built in

Cost: $4,108.32 delivered to Bethlehem, Pennsylvania
Chimney cap final weight 141.8#
(base ISD: 28.5" X 41.5", or 8.21 sq')
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Cline - (11/16 to 2/17)
A Matching Set of King & Queen Crown Style Chimney Pots

Quoted $5,010 - 16" wide flue w/32" & 35" wide crowns
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Schuh - (8-11/16)
A set of 3 Tuscany style w/double tier base and a 6/12 hipped roof

Cost: $17,434.75 delivered and installed in Gillette, Wyoming
Chimney cap final weight 216#, 212.5#, and 278.8#
(base ISD: 2 at 41" X 53.25", or covers 15.16 sq'
and 1 on the right at 52.5" X 64.75", or 23.61 sq')
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King - (4/16)
A hip roof w/oversized rivets

Cost: $3,731.05 installed in Beaverton, Oregon
Chimney cap final weight 129.6#
(base ISD: 37.25" X 41.25", or 10.67 sq')
Koch - (1/16)
A concave hip roof shape w/oversized rivets

Cost: $7,854.55 delivered to Forest Lake, Minnesota
Chimney cap final weight 244.5#
(base ISD: 44.25" X 54", or 16.59 sq')
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Schoener - (12/15)
Tuscany 6 arch style w/double tier base
and a 8/12 hipped roof


Cost: $4,250.20 delivered to West Chester, Pensylvania
Chimney cap final weight 140#
(base ISD: 29.25" X 49.5", or covers 10.1 sq')
Larsen - (9/15)
Fountain Pen style company logo design for over a natural gas flue w/fresh air intake

Cost: $3,111.20 delivered and installed in Sandy, Oregon
Chimney flue cover final weight 83.2# and 9' 4" tall
(square base ISD: 28.5" X 28.5", octagon flue 14" wide X 48" tall, weatherhead18.5" wide)
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Bishner - (11/15)
60" wide twin wall octagon fire pit hood w/12" flue, roof flange, and & chimney cap

Cost: $7,484.60 delivered to Petoskey, Michigan
Chimney hood & cap final weight 204#
(flue ISD: 12" X 104" long, OSD 60" & 15.75")
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Larsen - (8/15)
Our first 4 arch (on one side) Tuscany style w/double tier base and a 6/12 hipped roof

Cost: $6,200 delivered and installed in Sandy, Oregon
Chimney cap final weight 210#
(base ISD: 27" X 96", or covers 18 sq')
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Hallett (proudly shown in this photo) - (7/15)
10 arch Tuscany style w/internal pan, taller arches, double tier base, and 6/12 hipped roof

Cost: $8,824.50 w/o crate or freight. Went to Napa, California
Chimney final weight 405#
(base ISD: 54.5" X 84", or covers 31.8 sq')
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Chimney Caps page #5

'The More Sofisticated Years'

Spurgeon - (4/15)
Bird house style w/double tier base for an 8/12 roof

Cost: $4,800 delivered and installed in Banks, Oregon
Chimney final weight 172#
(base ISD: 24" X 24", 80" tall octagon flue 16" wide w/weatherhead)

LoVullo
- (12/14 - 1/15)
Square column style w/internal pan, triple tier base, and 12/12 hipped roof

Cost: $7,828.10 delivered to Grand Island, New York
Chimney cap final weight 257.4#
(base ISD: 49.75" X 68.5" X 82" tall, or covers 23.7 sq')
LoVullo - (7 - 11/14)
Tuscany 10 arch style w/internal pan, double tier base and 6/12 hipped roof

Cost: $10,869.40 delivered to Grand Island, New York
Chimney cap final weight 370#
(base ISD: 67.75" X 92.75", or covers 43.6 sq')
Goodwin - (10/14)
A pair of Greek 6 column style w/internal pan, double tier base and 6/12 hipped roof

Cost: $11,377.20 delivered to Point Pleasant, New Jersey
Chimney cap final weight 214.5# and 232.5#
(base ISD: 37.75" X 72", or covers 18.88 sq', & 44.5" X 72", or covers 22.25 sq')
Aumann - (8/14)
A clay flue mounted natural gas chimney cap w/fresh air intake below main weather-head



Cost: $1,019 installed
(hood 18" wide, base ISD: 12.5")
LoVullo - (7/14)
A concave hip roof shape w/oversized rivets
Eagle weathervane w/custom fish in mouth added

Cost: $3,850.52 delivered to Tierra Verde, Florida
Chimney cap final weight 109#
(base ISD: 28.5" X 34.75", or 6.9 sq')
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Davis - (12/13 & 6-7/14)
A set of 3 Kensington style chimney caps


Cost: $14,589.67 delivered to Bedford, NY
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'
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Solari- (11/13)
Tuscany style arches w/squared piping trim, and 6/12 roof cover

Cost: $3,212.55 for both - Client pick up from Salem, OR
Final weight 62.2# & 92.8#
(attachment bases ISD: 21.25" X 25.5" & 25.25" X 40.75" , or 3.76 sq' & 7.22 sq')
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Rossi- (4/13)
An industrial style concave hip design w/6/12 roof graduating steeper w/oversized
rivets to match their mantle I made with SS fire screen in a tubular copper frame

Cost: $5,010.25 for this 3 part: chimney cap, mantle, & fire screen
delivered to Palos Verdes Estates, CA
Chimney cap final weight 105.2#
(attachment base ISD: 31.75" X 31.75", or 7 sq')
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Lulich- (12/12)
Tuscany 6 arch style w/double tier base and a 6/12 hipped roof

Cost: $3,527.70 delivered & installed in S. W. Portland, Oregon
Final weight 133.8#
(attachment base ISD: 20-7/8" X 56-3/8", or 8.2 sq')
Saved $122.30 - less material used than quoted
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Fennern - (11/12)
chimney cap w/16/12 gable end roof & SS spark arrest screen


Cost: $3,031.48 delivered & installed in Newberg, Oregon
Final weight 133# w/o weathervane
(attachment base ISD: 25.7/8" X 37-3/4", or 6.82 sq')
Saved $470.67 - more material used than quoted
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Muenster - (8/12)
Basic chimney cap w/6/12 hipped roof & SS spark arrest screen


Cost: $4,150 delivered to Sioux Falls, South Dakota

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
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Bucchioni - (7/12)
Pair of Greek arch style w/6/12 hipped roof hinged from base

Cost: $6,471.10 delivered to Woodbury, Connecticut
Final weight 233.5# w/o crate, 430# w/crate
(attachment bases ISD: 23.75" X 38" & 26" X 48.25" , or 6.27 sq' & 8.71 sq')
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Finn - (2/12)
Simplified Tuscany arch style w/6/12 hipped roof w/Client's Company Logo

Cost: $5,500 delivered to Vienna, Virginia
Final weight 233.5# w/o crate, 430# w/crate
(attachment base ISD: 33" X 80", or 18.33 sq')
Saved $550.50 for more copper used than quoted
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Sarkinen - (1/12)
A rugged style concave hip design w/11/12 roof graduating steeper
w/oversized rivets to match their mantle I made a year prior
Stork weathervane made by some one else.


Cost: $2,722.17 delivered to St. Michael, Minnesota
Final weight 78.2# w/o crate
(attachment base ISD: 25.25" X 25.25" , or 4.4 sq', roof OSD: 30" W) .
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Chimney Caps page #4
'The More Refined Years'

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Morgan - (12/11)
Stylish low profile design w/6/12 hipped roof for over a natural gas exhaust


Cost: $2,126.52 - client pick up. Final weight 119.4#
(attachment base ISD: 35.75" X 42", or 10.4 sq', roof OSD: 41.25" X 48")
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Lawton - (5/11)
Simplified Tuscany arch style w/10/12 hipped long ridge roof


Cost: $4,439.20 delivered to Saunderstown, Rhode Island
(attachment base ISD: 28" X 38", or 7.4 sq')
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Birger - (9/10)
Tuscany 8 arch style w/double tier base, and 6/12 hipped roof

Cost $5,316 w/client pick up
Collinsville, Illinois
(base ISD: 2' 1.75" X 8', or 17.2 sq') Final cost was $684 less than estimated
Raban - (10/10)
Simple square flue liner mounted


Cost: $461.25 delivered to Kent, Washington
(attachment base ISD: 12.25", or 1.1 sq')
Wolfgang - (6/10)
Octagon roof mount screened vent
cover for kitchen or natural gas

Cost: $550 part only Portland, Oregon
(flange: 6/12 pitch roof mount, 6.5" ISD)
Pagano - (5/10)
1/2 scale Lighthouse style chimney cap
w/Morgana style finial and LED lighting

Contact me for the cost of this project
delivered to Seneca Falls, New York

(base ISD:: 4' 11 , or 16 sq'. Catwalk OSD: 6' 6")
Saved $3.3k in discounts for large unique design
Witkiewicz - (3/10)
Covered Bridge style w/chimney flashing kit and cricket


Cost: $3,018.50 delivered to Somers, New York
(base ISD: 28" X 66", or 12.8 sq')
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Peabody -
(3/10)
A less simplified arch style than Reeves cap
Cost: $4,847.80 delivered Westport New York
(bases ISD: 31.25" X 51.25", or 11.1 sq'
& 31.25" X  39.25", or 8.5 sq')
Saved $1,326.40 for being decisive before contacting us and volume discount
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Swanson
- (10-11) 2 chimney caps/09)
Tuscany arch style w/8/12 hipped roof
Cost: $9,034 delivered to Waco, Texas
(base ISD: 38.5" X 49" ISD, or 13.1 sq') . Tuscany arch style w/12/12 hipped roof  

(base ISD: 38" X 51", or 13.5 sq') Saved $2,785.72 on both for being decisive before contacting us and volume discount
Blair - (2/10) Bird House style w/12/12 cover & cap

Cost: $2,900 installed Portland, Oregon
(base ISD: 36" X 81", or 20.3 sq', flue OSD: 10")
Nelson - (12/09) Chapel bell style w/finial
Cost: $3,701.88 delivered to Tampa, Florida
(Flue OSD: 14",  45" pan, or 14.1 sq',
with a 34" W bell)
 
Bardana - (10/09)
Pair of Tuscany arch style w/6/12 hipped roof

Cost: $8,863.28 - set of 2 chimney caps installed in Lake Oswego, Oregon
(base ISD: 29.5" X 41.25", or 8.5 sq', & 30.5" X 121.5", or 25.7 sq')
Saved $2,706.40 on both for being decisive before contacting us,
being the first to have us build this triple arch design, and volume discount
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Chimney Caps page #3

'More Creative Designs'

(after I started to using hardwood in the base/skirt)

Graham - (7/09)
Gable style w/16/12 roof
Cost: $2,136.50 installed Portland, Oregon
(base ISD: 22" x 51", or 7.8 sq')

Saved $347.30 for gutter combo discount
Nelson - (9/09)
Chess piece 'Bishop' style w/4/12 roof
Cost: $2,616.04 delivered Tampa, Florida
(flue OSD: 12", base ISD: 36.75" x 38.5" = 9.8 sq')
O'Brien - (6/09)
Tuscany arch style w/8/12 hipped roof
Cost: $2,548.36 delivered Arlington, Massachusetts
(base ISD: 31.25" x 31.25", or 6.8 sq')
Saved $299.60 for being decisive before contacting us
Lee - (5/09)
Mini Lighthouse style w/6/12 roof

Cost: $237.50 delivered to Birmingham, Alabama
(Made to be soldered over a flat copper roof,
inside base: 8" tapered  in for a 3" gas flue,
16" tall under SS screen w/10" wide cap)
Besio - (3/09)
1/3 scale simplified Lighthouse style chimney cap over odd triangular shaped base w/low profile bell roof and Morgana style finial

Cost: $7,500 - delivered Glen Arbor, Michigan

(base ISD: 6' 11" x 6' 3", or 34 sq')
Saved over $2k from more copper used than estimated
.Fenley - (6/08)
Mini Lighthouse style w/6/12 rooff

Cost: $600 - w/o delivered to Mulino, Oregon
(flange: 5/12 pitch, base ISD: 22" x 24",
made to fit over an 8" SS flue pipe)

A Client in Connecticut (name and City removed at client's request.
First time ever)
(6/08Tuscany arch style w/6/12 hipped roof)
A Tuscan style copper chimney cap for Gasior in Middletown, Connecticut

Cost: $2,980.30 delivered to a City in Connecticut
(base ISD: 22" x 39", or 6 sq')

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Corker - (3/08) Tuscany arch style w/8/12 hipped roof A Tuscan style copper chimney cap for my client Corker in Mechanicsville, Virginia
Cost: $3,304 delivered to Mechanicsville, Virginia
(base ISD: 35" x 43.5", or 10.6 sq')
Saved $611 for being decisive before contacting us
Stone - (1/08)
Tuscany arch style w/6/12 hipped roof
A Tuscan style copper chimney cap for Stone in Summit, New Jersey

Cost: $2,503.20 delivered to Summit, New Jersey (base ISD: 31.25" x 31.25", or 6.8 sq')
Saved $561 for being decisive before contacting us
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McLaughlin - (12/07)
Greek column style w/6/12 hipped roof
A Grecian style copper chimney cap for my client McLaughlin in Staten Island, New York
Cost: $4,537.24 delivered to Staten Island, New York
(base ISD: 61.5" x 26.5", or 11.3 sq')

Saved $61 for
allowing us to make this unique design
Reeves - (11/07)
Simplified arch style w/6/12 hipped roof
A sudo Tuscan style copper chimney cap for Reeves in Springfield, Illinois

Cost: $2,944 delivered to Springfield, Illinois
(base ISD: 59.75" x 30.25", or 12.6 sq')

Saved $368 for
allowing me to build this first simplified Tuscany arch style
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Willard (8/07)
Chess 'King' style chimney w/roof flange
A King style copper chimney cap for Willard in Grass Valley, California

Cost: $3,265 delivered to Grass Valley, California
(made for a 12/12 pitch roof, inside base 24" x 24", w/13" flue pipe over a 12" wide chimney pipe)
Matury (6/07)
Bird House style chimney w/roof flange
for a12/12 pitch roof line
 A Birdhouse style copper chimney/cap for Matury in Munster, Indiana

Cost: $3,116.60 delivered to Munster, Indiana (base: 20" x 20" ISD, 14" wide flue over a 13" chimney pipe)
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Berrigan - (2/07)
Tuscany arch style w/10/12 hipped roof
A Tuscan style copper chimney cap for Berrigan in Stone Harbor, New Jersey

Cost: $4,617.43 delivered to Stone Harbor, New Jersey
(base ISD: 58.5" x 45.5", or 18.5 sq')
Saved $791 for
for more copper used than estimated
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Gross - (12/06 - 1/07) Pair of Tuscany arch style w/8/12 hipped roof The larger Tuscan style copper chimney caps of a set of 2 for Gross in Chester, New JerseyThe smaller Tuscan style copper chimney caps of a set of 2 for Gross in Chester, New Jersey
 Cost: $8,477.75 - set of 2 delivered to Chester, New Jersey  
(bases ISD: 38.5" x 79", or 21.1 sq', & 43.25" x 43.25", or 13 sq')
Saved $1,303 for being decisive before contacting us and volume discount

Chimney Caps page #2
'The Early Years of CBD'
(prior to using hardwood in the base/skirt)

Keep in mind most of these chimney caps shown below were made back when copper was 1/2 the cost

Matovich part 1 & 2 - (11/11 - 11/30/06)
Pair of Tuscany arch style w/10/12 hipped roof The Tuscan style copper chimney caps set of 2 for my client Matovich in Setauket, New Jersey
 Cost: $8,500 for the set of all 3 delivered to Setauket, New Jersey
(bases ISD: 36.25" x 64", or 16.1 sq', and 20.25" x 32.75", or 4.6 sq';)
Saved $3047.05 for being decisive before contacting us, volume discount,
and using a lot more copper than estimated
Matovich part 3 (12/06)
A Tuscan style copper  lighted ccupola for Matovich in Setauket, New Jersey
 lighted Cupola w/weathervane support
(inside base: 30" x 20")
Fultz - (9/06)
Corner column style w/4/12 hipped roof  A simple design copper chimney cap for Fultz in Richmond, Virginia
 Cost: $1,940 delivered
to Richmond, Virginia

(base ISD: 18" x 35.5", or 4.4 sq')
Saved $330 for using a more copper than estimated
Eastaff of LEA Construction - (7/06)
Pair of Low profile style w/4/12 hipped roof A set of 2 low profile copper chimney caps for LEA Construction in Brookings, Oregon
 Cost: $3,410 - Client pick up - Brookings, Oregon 
(bases ISD: 48" x 80", or 26.7 sq', and 40.25" x 40.75", or 11.4 sq')
 Takhar - Fire Pit Hood (3/06)
Square 6/12 hipped cover hood

Takhar - Copper Fire Pit Hood, Bemidji, Minneapolis
 Cost: $2,900 delivered to Bemidji, Minneapolis
(hood OSD: 62.5" x 62.5")
Takhar - Flue (part 2)
Takhar - Copper Fire Pit Flue, Bemidji, Minneapolis
 Square Flue Cost: $2,020
(flue ISD: 9", shell OSD: 12", 106" T)
Takhar - Roof Flashing (part 3)
Takhar - Copper Fire Pit Flue Flashing, Bemidji, Minneapolis
 Cost: $480 32oz Copper Roof Flange 
(flange size OSD: 36" x 36")
Takhar - Chimney Cap (part 4)
Mini Lighthouse style

Takhar - Copper Fire Pit Chimney Cap, Bemidji, Minneapolis
 Copper Chimney Cap Cost: $480
(base ISD: 12.25" x 12.25")
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Kensington 28 units - (3-6/06)
Monolith style

Kensington 28 units in  Sunnyvale, California
 Cost: $45,279 delivered to Sunnyvale, California (base: 43" x 43" ISD, or 12.8 sq')
Saved over $45k for volume discount, using a lot more copper than estimated, and personal delivery
Trainor - (2/06)
Greek column style w/6/12 hipped roof

A Grecial style copper chimney cap for Trainor in Fairhope, Alabama
 Cost: $4k delivered to Fairhope, Alabama
(base ISD: 41" x 69", or 19.6 sq')

Saved over $1,000 for this unique design, and using a lot more copper than estimated

My First Chimney Caps page #1

'prior to CBD; made for our local gutter Clients'
(boy, I've come a long way since then. There are several details I would never do again. Such as using a flimsey copper gutter screen)

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.Silbernagel - (1/06)
Tuscany arch style w/6/12 hipped roof A Tuscan style copper chimney cap for Silbernagel in Dundee, Oregon

Dundee, Oregon

(base ISD: 34" x 40", or 9.4 sq')
LEA Designs 1 (12/05)
Mini Tuscany arch style w/12/12 roof
My first Tuscal style copper chimney cap for Pascoe in Santa Ana, California
 Delivered to Santa Ana, California
(base ISD: 25.25" x 26.25", or 4.6 sq')
LEA Designs 2 (1/06)
Clay flue mounted Royal Crown style
w/weathervane mount
My first Tuscal style copper chimney cap for Pascoe in Santa Ana, California
 Delivered to Santa Ana, California
(base ISD: 14.25")
Smith (11/05)
Gable end style w/8/12 roof A copper chimney cap for Smith in Yacolt, Washington  Client pick up Yacolt, Washington
(base ISD: 29.5" x 35.75", or 7.3 sq')
Gamanara (3/05)
Simple 6/12 octagon hipped roof A small copper chimney cap for Gamenara in S. E. Portland, Oregon
 
S. E. Portland, Oregon
(base ISD: 9")
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Lucey - (2/05)
Gable end style w/6/12 roof A copper chimney cap for Lucey in N. W. Portland, Oregon
Cost: $950 installed N. W. Portland, Oregon
(base ISD: 17.5" x 42", or 5.1 sq')

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Szakacsy (7/04)
Covered Bridge style w/sharks peak roof
 

Client pick up Moorpark, Ca
(base ISD: 31" x 75", or 16.1 sq')

Chimney Flues - (9/04)
Chess piece style chimney pots A set of 3 copper chimney flue extensions/caps for Howard in S. E. Portland, Oregon
S. E. Portland, Oregon
(each base ISD: 11.75" x 15.75" X 3, or 3.9 sq')
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Tullier (6/04)
Gable end style w/4/12 roof A copper roof cover for a long chimney for Tullier in N. W. Portland, Oregon
N. W. Portland, Oregon

(covers 20.25" x 147", or 20.7 sq')
Wasserman (2/02)
Covered Bridge style w/4/12 roof A large simple copper chimney cap for Wasserman in S. W. Portland, Oregon S. W. Portland, Oregon
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1996
Installed - S. W. Portland, Oregon
S. W. Portland, Oregon
1996
Installed - Fairview, Oregon
Fairview, Oregon

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Introduction

What sets you apart from the rest? We are not a bargain outlet for generic mass produced chimney caps with flat tops from foreign lands made by slave labor working for $0.50 an hour, but we are not over-priced for what you get either.

Given the importance of such a substantial project that may be the crowning jewel on top of your house we understand how important this is for you. Besides being self proclaimed hippies (w/o substance abuse), we have a profound compassion for others (see: mind-temple.com). 

David's been growing his hair out to donate for cancer patients over the last decade, and my Wife Tia is a practicing Midwife.  David also has a unique talent for math, mechanical comprehension, and spatial arrangement, as well as a lot of experience in sheet metal fabrication doing his own design work over engineering these to exceed Building Code in most every aspect.

It is difficult to find the best balance between looks, function, strength, durability, and cost. Factors that do not naturally blend together, but rather oppose each other. I do my best to implement each of these factors.

I place a very high priority on strength. What would be the point of using a life-time metal like copper if it is made with such just a thin copper to save a few $, which will dent or warp from excessive heat. I strive to build these to last well over a century. I build the strongest and heaviest copper chimney caps you will find, along with custom styling ont color="#800080">(depending on the clients taste) without charging extra for that personalized design work.

Serious inquiries only please, as it often takes over an hour or two in order to make all of the careful calculations and write up a quote. That is even after our clients have taken the time to provided us with good clear information and photos to work from, with most of our clients not being local to us here in the Portland, Oregon area.

 If you are not local to us the installation will have to be handled by you, or you'll need to find

 a local contractor to handle it. To find a local installer in your area with positive reviews from other Homeowners you can try some Consumer Protection web sites like A's List and Insider Pages.

Read reviews of Dmr Gutters

Installation is not nearly as hard and dangerous as you might imagine with the right equipment and tools. I've found a local crane operator that has only charged us his minimum $200 for even a double chimney cap installation. Then there's just to check the level and tighten the screws. The installer may not be able to stand on your steep roof anyway, so it should not matter if the roof is clear of snow. With as heavy as these are and the taller base/skirt I make these chimney caps with they are much less likely to blow off in a wind storm even if the screws were not to be tightened at all.

Do I need to pick from just the designs shown here? No. We applaud originality, so don't be shy to ask for a design not yet displayed here on our web site, or some combination or variation of styles and details. We do not store chimney cap templates for generic designs, so I do not offer discounts for a copy of the same design used before, since I'd still have to draft it all out from scratch to fit your specifications anyway.  This insures the authenticity or originality of each chimney cap made. Other than the 28 chimney caps we built for the Kensington project  (shown below) we have not had a chance to make a second chimney cap of the exact same design and measurements:

Kensington 28 units in Sunnyvale, California

A Tuscan style copper chimney cap set of 2 for Matovich in Setauket, New Jersey

Our Main Advantages: (a) Better communication through this comprehensive web site and swift detailed e-mail replies with photos and diagrams. Having personally spent thousands of hour developing the most comprehensive web site of it's kind with thousands of photos. There are even numerous detailed step-by-step fabrication web pages to show you just how I work my craft and the thought that goes behind each project. Actual cost break-downs displayed here to give you a good idea of what these really cost for a no pressure anonymous price comparison.
(b) The actual Coppersmith who has lots of installation experience willing to spend the time to work out these details with you through e-mail and over the phone personally, so that you are not going through a middleman sales-person or feeling rushed. You'll be asked the right question, so it turns out the way you wanted, and there is less chance you'll run into problems while installing. My aim is for you to feel we have done our best to explored all the options to suit your needs before I start fabrication and have placed a ceiling cost, so there are not unpleasant surprises like you find with most construction project over-runs that are all to common. Little to no pressure to up-sell you. I'm too busy to mess around with that nonsense. I'm often amaze with what I  manage to create when working together with the inspiration from my clients.
(c) Taller, stronger, and heavier base/skirt sections than any you've seen. I build them this way for additional weight and a more secure attachment. Even without the benefit of the stainless steel fasteners (which I provide); a taller base/skirt it is a lot less likely to become dislocated in high winds, since it would bind up before it could fly off, even if the fasteners fail or they were not tightened down right.
(d) Stronger engineered internal cross bracing framework for good roof support for snow loads or minor impacts. You may find more expensive chimney caps elsewhere that look very fancy, and of course some cheaper ones, but you will be hard pressed to find solid copper chimney caps built to last like ours.
(e) No solder used! I am astonished to see so many other fabrication shops use solder to assemble a chimney cap, when  they must know how solder melts at just half the temperature of aluminum, which is only used for low temp natural gas exhaust. It would logically suffer from the high heat that can be produced inside a chimney cap; causing it to literally fall apart.  I design our chimney caps to be sealed from the rain with healthy overlapping seams riveted together like aircraft construction. At close inspection it may not be the prettiest look, but positioned up 3 stories high on your chimney after it has tarnished within a couple months time makes this hardly an issue and well worth the advantages. In many cases I am able to hid most of the rivets holding it together.
(f) Designed as seamlessly as possible for more strength and a better weather seal. Even if it may not be the most efficient use of these sheets of copper.
(g)  I seem to be less greedy with a lower overhead than most other larger sheet metal shops. Our prices have shown to be less than other custom shops across the country per square foot of copper used. I enjoy my work and would rather not just become a manager of people.
(h)  I believe we are the only shop that has the integrity to weigh the chimney cap upon completion to adjust the quoted price lower to reflect only the copper used in your chimney cap at the rated cost per square foot.  This way you are not paying for the wasted cut-off copper used to make it, let alone a loosely inflated estimate you'll get from other shops. Although, it is common for me to have used more copper than predicted, but you are still protected by the quoted ceiling cost, unless changes were made to the project; with your approval of course.

Shipping: You will see most of our clients are not local to us here in Portland, Oregon, so these prices include the shipping crate and freight. I go out of my way to build the best custom shipping crates you are likely to see, in order to avoid unpleasant delays resolving a damage claim. I pre-drilled and screw a wood frame together w/Gorilla Glue, covered with a hardwood shell that's glued and screwed over this frame (examples shown below). So far only 1 chimney cap had been seriously damaged by DHL in 2006, and 1 minor dent by Roadrunner Transportation trucking back in 2009.

Client Satisfaction:

I cannot guarantee your project will be flawlessly beautiful.  I am human after all. I send out digital progress photos as I'm building most project for client approval well before it ships. I will guarantee it will fit the specification you provided, and built as well as I know how; given the limitations of your budget.  In the case of an issue arising from the client being unsatisfied with a project before it ships; I'll usually bend over backwards to make things right for them, or refund most of the deposit if I have not already finished building it.

Fortunately this has only been a problem with one turret roof cap client (2/08) where we were not able to resolve our differences, and I refunded her deposit, so it could happen. I cannot possibly cover all possible issues here, but if a clients aesthetic concerns conflicts with important design quality I will not compromise my standards. Even if that client is fine that it would void the warranty.

You can cancel a contract at any time before fabrication has begun without explanation. All but 10% reservation fee of the deposit is refundable. The deposit paid may not be refundable after I have begun cutting and bending metal for your project, but I will not hold you responsible for the balance before it has shipped.

Company logo name plaque

Here is a commemorative plaque that Teresa Trainor had requested early in the quote process of her $4k copper chimney cap order. We had this sheet of copper engraved at the cost of $80 for her architectural art sculpture we had made. So far she is the only client to request this archival detail, so we have not seen the need to get the tooling for making these plaques for all our projects. I try to keep my ego in check. It would be a $100 option added to the cost.

What about the need for Chimney Sweeping?

This is a question I get probably more than any other. These chimney caps I build are removable with minimal effort, aside for being several stories up off the ground. Of course depending on how large it is or how steep your roof is. I even made one pair for a client with the top portion hinged for easy access to the flues, but they lost the advantage of a spark arrest screen. Although, you should not have to worry about needing to take it off for these reasons:

I have been up on thousands of roofs and worked on many chimneys, but I'm not a professional chimney sweep, nor have I ever met one in my travels. Once I tried out sweeping a chimney flue for a client about 20 years ago. It was a messy job at best. I felt I was wasting their money, not being sure how this helps or what good it served. I use to have a set of brushes, but not sure what happened to them. I've even rebuilt several brick chimneys from the roof-line up, as seen in the photo here.

Personally I have never seen a chimney so clogged with what ever they would need to sweep it out for that would have cause an exhaust flow restriction. I've never seen even more than 1/4" build-up on the inside walls of a brick chimney, so I never understood this whole issue. I have heard from clients who were told how creosote build-up can cause a chimney fire, but I've never actually heard of this happening. It may just be a scare tactic to sell you something you don't need. Even if it did catch fire why would that be a problem? Wouldn't it be contained within the chimney? I know when a house does burn to the ground for some other reason the chimney is the only thing left standing. If that creosote did actually burn off wouldn't that be a self cleaning chimney? Maybe that's why I've never seen a substantial build-up inside a chimney.

I have heard about some problems with metal flues becoming dislocated inside the wood chimney box and burning the house down if not just causing a great deal of smoke damage. Or that metal flue pipe becoming a fantastic lightning rod with the same result, so I cannot say I'm a big fan of metal flues, which are rarely sealed properly at the top. Hence the work I do to improve that one issue.

I know it's better to be safe than sorry, but from what I have seen you are better off investing in getting your rusty steel roof flashing replaced with a rust free metal, or having a chimney cap made for it with a spark arrest screen that would be more helpful. A decorative copper chimney cap would add some advantages as well as enhance the appearance of your home; as the crowning jewel, but that is subjective of course.

I hope this helps.

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David Rich working on a copper chimney cap

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What metal is best for chimney cap construction?

Main Factors:It is hard to find the best balance between style, longevity, strength, and cost. These factors do not naturally blend together. I work to reach the best balance possible on all the projects I build.

(a) Chimney caps need to handle a great deal of heat, unless the exhaust is just from a natural gas heater. I have personally stoked up a wood stove so hot the steel exhaust pipe was glowing orange and lit up the living room. It was about 15 years ago and I was not trying to test this theory. I was just burning some paper garbage.  You can see these statistics at a web site called Online Metals.

Most metals handle high heat well, but steel commonly has a thin zinc coating for rust protection that melts at a very low temperature and will result in rust stains or worse.

(b) A ticker heavier sheet metal is most always best, so that it is strong and less prone to wind damage. But that of coarse greatly increases the cost of the metal used and the shipping charges. It also makes it harder to cut, drill, and bend, so finding the best balance is important. That is why I use more internal bracing, in stead of just thicker copper sheet metal than I already use.

(c) The cost of the metal type is a small consideration from your end for any custom work like this. Most of the cost is the design, custom fabrication, a shipping crate, shipping costs and installation. A 500% increase in the metal cost would only have about 20% increase in the total cost, so a better metal is by far your best value any way you slice it. Anything less is a waste of money. My custom copper chimney caps will normally increase the resale value of houses more than the cost difference, so you can make a profit from using better materials that will last. Even short term.

(d) A long life metal that will stay looking good decades later and need little to no maintenance is a much better value, but even more so in just the cost of labor to replace cheaper units more often. Rust stains from common steel units can be very unpleasant if the unit is not replaced every 10 to 15 years. A well made copper unit should last well over a century. That saves you the hassle of 7 or more replacement and installation in that time, being heirloom quality.

Steel (very poor choice, yet most common): Galvanized or high temperature painted steel is the most commonly seem metal used by far. Mainly because it is so cheap, quick to spot weld together, strong, and handles high temperatures well. Few homeowners take the trouble to look into these details, so contractors will use the cheapest materials they can get away with. In most States the contractor is only required to provide a 1 year warranty. Steel cost less than 1/6th of copper, but in the long run it actually costs far more to the homeowner with the cost of replacement fabrication and repeated installation each decade or so. Also, there's the added cost of rust stain removal and or repainting.

The galvanized steel cap shown here was less than 15 years old.  It was so rusty, pitted, and worn thin that I could crush it with my bare hands like an aluminum pop can. You can see here dozens of daylight pin-holes through the metal (photo above left).  Two of the three bracing that held this hood up had disintegrated.  The strap clamp had disintegrated so badly that we were able to lift it off the stainless steel chimney pipe it was attached to without loosening the clamp.  The worst part was how it left terrible rust streaks down the sides of the stainless steel chimney pipe and on the roofing that are now pretty well permanent (photo above right). I tried to use a wire brush in it, but it did not seem to help.

The simple flat roof chimney cap most commonly seen like in these photos below is not the type of chimney caps I make.  Those are small generic size caps that are mass-produced and sold in many hardware stores.  It is normally designed to bolt onto a flue liner, but most of the chimneys I've seen do not have a flue liner tile protruding up over the bricks to attach that specific type of cap to.

This is a stainless steel chimney cap on a house I had replaced the gutters 12 years prior.
The left cap had blown off and the one on the right was crushed by a branch hitting it.

That type of cap may work on your chimney, but it's not very decorative. It is fine for an inexpensive temporary solution. Steel can handle a good deal of heat, with a melting temperature of 2,500 degrees F. Although rain and heat will dissolve the zinc galvanizing away. The zinc melts off at only 787 degrees.  Even though the high temperature paints can handle more heat than a zinc coating, it is not much better, since it is prone to suffer UV damage from the sun and oxidization.  You can see these statistics at a web site called Online Metals.

If you let it go too long steel chimney caps will rust and make unsightly permanent rust stains down the side of the chimney and on the roofing shingles around it, that are near impossible to remove. Eventually it will deteriorate so badly that it will literally fall apart. If you factor in the labor cost of replacement each 10 to 15 years, spending $3,000 on 1 copper chimney cap is cheaper than getting an inexpensive $1,500 steel cap built the same way.  A steel chimney caps is not a good value for your dollar.  Not when a copper chimney cap should last well over 100 years, if built well. 

Steel is good for repeat sales; due to it's planned obsolescence.  That's the same reason we do not see more car bodies made out of aluminum, like with the Acura NSX sports car pictured below.

Aluminum (good for low temp natural gas exhaust only): Aluminum will take much more heat than a zinc coating on steel; at 1,218 degrees F.  But for use over a wood burning chimney it can reach such temperatures that would warp the aluminum sheet metal or perhaps melt it.  I have personally stoked a small wood stove so hot that the black painted steel stove pipe was glowing orange, and lit up the room.  And aluminum pipe would have melted at that temperature. If the chimney is only used for venting natural gas exhaust, thin aluminum ducting is commonly used, since the heat requirements are so much less and fairly consistent.

Aluminum would also need to be very well built and attached, since it is a lot softer metal and a lot lighter, and therefore is more prone to wind damage. Aluminum is great for aircraft construction where weight is very important, but it is not an asset for a chimney cap.

Brass (good) Brass is made of 70% copper and 30% just a soft zinc metal to help reduce the cost, which gives it that yellow look and makes it easier to bend, or dent.  Being a softer metal it would requiring a little thicker sheet to have the same dent resistance; making brass not really much of a cost savings. It will still tarnish and turn black with age with perhaps less of that chalky green tarnishing. It also has a lower melting temperature, so it will not handle heat quite as well.
Stainless Steel (better):
This is a good strong high temperature metal, but it is just as expensive as copper; costing 6 to 10 times more than just galvanized steel.  It may look good outside a diner car, but one of the biggest drawbacks to stainless steel is how it will stay bright and shinny, will get dirty, and mildew on the North side (just like in this photo taken on the Pacific Coast, over a church near Cannon Beach, Oregon). It is easy enough to clean once you are able to safely access it, but that can be enough of a hassle that it just doesn't happen.

Stainless steel is preferred by most sheet metal shops because is quick and easy to just spot-weld together, so most shops will opt for stainless steel when forced to work with a rust free metal. As with copper other shops will usually use very thin sheets of stainless steel to to work with in order to help reduce the cost and make it a lot easier to cut, bend, and drill. The thinness of the metal will tend to show a lot of irregularities and buckles on a flat surface. Hence the big  'X' bend commonly seen in these flat panels. Most people think it is a design feature, but that actually has nothing to do with why they bend that 'X' through the larger metal panel.

One of the cautions with stainless steel products is how many clients have been swindled by getting just steel, which will begin to rust within a few years. Well past any chance to resolve a dispute over that fraud. Even if it is made with a high grade stainless steel that will not attract a magnet the fasteners may not be SS. Any product is only as good as it's weakest link.

New Artisan Fire Pizza Oven

Here is a example of a very nicely built 30" wide pizza oven, but at over $6k it cost more than one of my copper chimney caps that are 4X larger w/truck freight included. I'm flattered if their design was inspired by my work shown just below, but they deny it of course.

Copper (best): Other than cost and tricky handling copper is the best value for your money, since copper is one of the few metal meant to be seen in it's natural state or after oxidization. Being the same cost as stainless steel it seems the clear choice when given this choice.  The fabrication may cost a little more, since it is not as easy to work with. Copper will tarnish to a nice satin brown within a few months of exposure to the elements. The striated chalky green patina actually takes several decades to form.

We fabricate most of our custom copper work in 20oz copper sheets or thicker, which is 1/4th thicker copper than the standard 16oz copper normally used in the roofing industry.  Copper is a heavy and sturdy metal that handles around 2,000 degrees F. It needs no coatings over it for protection from the elements.  It has a melting point about 700 degrees higher than aluminum.

Unlike most other shops, we go to the trouble to rivet the overlapping seams together, since the melting point of the lead type solder is far less than even aluminum and less than the zinc coating on steel.  It would be terrible if the cap were to fall apart from the solder welds melting apart. We have seen plenty of evidence of this happening.  We have to design our chimney caps to be strong enough for high winds, and not to leak, without the use of solder or even caulk, and yet be easily removable for future cleaning and servicing.

Fabricators who are more about mass production will not work with copper, because it cannot just be quickly spot welded together like steel and stainless steel.  Handling is also tricky, since finger prints will cause the copper to tarnish sooner than the rest of the copper surface, making it spotty looking until it evens out.  So will wearing protective gloves while handling bare copper, but most of it will have a clear plastic film over the outside when you get it, that you simply peal off after installation.

New copper looks nice, but we have yet to find a good method to keep it from tarnishing.  Raw copper is actually more pink, but most people see it as an orange'ish color, since it has already has begun the tarnishing process by the time they see it just from the humidity in the air, beginning it's process to turn brown.  Any clear coat applied over the copper surface can be a problem, since it will not handle the heat well.  Even without the heat issue, the sun's UV rays and the elements will break the clear coat down before long, causing unsightly peeling and a spotty tarnishing where it has cracked and peeled off the copper surface.

Fortunately most people we have talked with seem to love the natural aged striated tarnish look that real copper gets, and some ask if we can pre-tarnish the copper here in our shop.  I explain how within a few months it will naturally tarnish, so it is not worth the added cost, but it can be done before shipping by applying an acid wash to pit the metal surface and cause this premature reaction. Not well advised if I may say.

Bronze (excellent, but too hard to work with): I have only seen very limited sources of bronze sheet metal stock, because it is not a malleable metal and therefore not good for bending. It is made of 70% copper with a mix of hardeners to make it stronger and more scratch resistant. Used more for casting sculpture.

Titanium (excellent, if you can afford it): Other than the fact I have not seen this sheet metal available because of such small demand given it's extremely high cost, it would be very hard to work with. As an example: I jokingly say how I would be willing to pay more for a titanium extension ladder to have a stronger lighter ladder, but the $5k it would cost replacing it when it gets stolen would be a real drag! I do have a titanium hammer and cats-paw that were about 4 times the cost of a normal steel tool of it's kind. They are great tools and I feel well worth what I paid. Real Titanium is truly an amazing metal, but they would have to be mass produced to be any where near feasible. The head on the hammer is still nearly as smooth as when I first got it. I am eager to see more products and tools made from this metal, but not many contactors are willing to pay 3 to 4 times as much for a tool for their employees, so few manufacturers are willing to make and market them. You also will need to be careful not to get swindled with an inferior grade or a complete substitute. Think of how many products are advertised using the word platinum or turbo charged (LOL). Real platinum is more expensive than gold for goodness sake!

Silver (well worth the brag points, if you can afford it): Again I have not seen a source for large sheets of sterling silver, because of the high cost and therefore low demand, but that would be pretty cool. It would still tarnish to a dark black and look much like aged copper, unless you hired someone to polish it each year. I'm game if cost is no object.

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Helpful Roofing Information For some valuable advice with regards to roofing and rain management issues check out our:

(a) Gutter Installation
(b) Gutter Debris Protection Options
(c) Roofing Quality Standards
(d) Chimney Flashing

(e) Moss Control & Treatment

web pages for answers and solutions that could save you thousands of $ and a great deal of anguish.

If you do find this information very helpful, feel free to send us a $ tip for the assistance we so freely have published on the web here for your benefit, like you might tip a waitress.  Heck, send us a gift certificate for a candle lit dinner for two.

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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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