CBD's Mahaffy Scupper Fabrication Photopage

These built-in scupper roof drains were made for Kevin Mahaffy. We passed around 50 e-mails w/diagrams back and fourth over the course of 7 months to work out all the details of this order for these custom products; going over size, shape, and metal thickness. I'm not one to rush a client and had to wait for his replies. The first photo on the left was one he sent to me to give me an idea of the look he was after, and the right photo is his house after installation. There are more wide shots below.

I sent him samples of copper to feel. He ended up going with a thicker 32oz copper for the bottom and sides for added strength, so that no wood structure needed to be made for support underneath the 18" that will stick out from the wall.

This first shot shows the stack of 32oz copper for your project. All 288.75 lb of it before it is trimmed off. There is some stacks of copper for the top and flashing flanges on the table behind it.

I racked my brain for a several hours trying different design ideas to get the best possible fabrication possible and still have a nice clean look from below. I decided to used some 20oz copper for the top cover and the upper and side flashing flange to help save cost where the heavier metal was not needed. I weighted the first unit and it comes in at 12.75 lb, from the 12.46 that I had originally estimated before I knew he wanted the top to be covered, so fortunately it did not change the cost my much.

These were made to be 9" wide X 6" tall and 24" long + the inside flashing flange. The total for these 24 custom roof drain scuppers was $6,305 delivered, which is just $262.71 each with the 10% discount I gave him for ordering so many of these units with the same dimension.

The detailed brake-down is like this:

32oz copper:
1 piece - 9.31lb X .5 = 4.66 sq' in the sheet for the bottom and sides
4.66 X $40 = $186.40

20oz copper:
1 piece - 24" X 10.25" sheet for the top and upper inside flashing
2 piece - 5" X 15" sheets for the side inside flashing
2.75 sq' X $25 = $68.75

Adjusted cost:
$186.40 + $68.75
= 255.15 for each unit
X 24 units
= $6,123.60
X .9 for 10% discount
= 5,511.24
+ $350 for the large shipping crate
+ $443.76 for the truck freight shipping
= $6,305 final total delivered
= $262.71 each

This black gaffers tape was placed over the caulk to make sure these would slide in without issue. These can also be soldered together. It is just a little trickier to do and discolors the metal.

I had to devise a good way to safely stack these in the smallest space possible. As it was this crate full of roof drains weighed about 600#.