Custom Copper Sheet Metal Fireplace Mantle Work Page

 Updated 9 / 2017

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Design:
These copper clad mantles are especially good for exterior applications, but are also used for indoor application for a clean look that can resist the radiating heat better than any varnished or lacquered wood. There
are numerous ways to go about building them as to the size and style taken into account, but they still need a solid wood base inside to resist denting. Some clients have us extra to texture the copper before attaching it to the wood substructure for an added cost of $20 per square foot for a rustic look. It also makes any new scratches or dents less noticeable.

The type of sturdy attachment also needs to be worked out, which is not too complicated to install, and hidden from sight, if possible.

As to Adding a Polish or Patina Look:
Personally I rather like the look of new shiny copper, but aesthetics is very subjective. Even indoors copper will gradually turn a satin brown just from the humidity in the air. Raw exposed copper is thought to be a living finish that is ever changing. Most of the work we do is for exterior rain management products, so the finish of the copper is not much of an issue. The copper we have access to is not polished, and will have tiny scratches in it, and perhaps a few small dents, as with anything hand-made, which cannot be perfect. It is a lot of work to polish this copper to a mirror finish, and this is not one of our specialties, so I cannot guarantee the finish will meet your satisfaction. This said; you will need to be a bit flexible with us on this detail. Copper can be polished at any point of it's usefulness, so imperfections is something you will never be stuck with. As long as you are willing to have it worked over until it meets your satisfaction. Just not a service we provide.

Numerous Clients have ask about having us hammer, color, or pre-patina this copper for an antiqued rustic look. There are numerous chemical combinations to get different colored patinas, or I can heat up this copper with a torch to get some interesting random rainbow colors on the copper surface. It would then need to be covered up with a clear lacquer over it to retain that specific look, but after discussing the pros and cons of this our Clients usually decided to forgo that costly option, as it may take numerous tries to get the desired look that I would need to charge for all that time required. If you are not local to us we can share photos of that project, but as you know that would not properly represent how this may look in person. If we get the tone you like it can be waxed to retain that look. Finger prints may make the copper turn darker in a spotty manner, but that can also be a rustic charming look some Clients like. Also, the heat from a torch can produce a rainbow of different colors in random patterns. If you decide you don't like that look it can be polished again to start over and find the look you like best, but this can be a long drawn out process, not easily done here in my shop.

Although, keep in mind copper left untreated it is 10X more anti-microbial than stainless steel, so there is virtually no cleaning needed. Without a lacquer your not stuck with that one certain look. I cannot guarantee what we achieved exactly what you had in mind, and we may not be able afford the time to redo it many times over to get the look you're after. Left untreated you have the option to polish it and then let it age, or change it with different chemicals, as listed here: http://www.sciencecompany.com/-W160.aspx

Also, a soft lacquer surface can easily become scratched and not handle the radiating heat nearly as well, which may look bad a decade later. An expensive PVD coating or gold gilding is the only type of good lasting scratch resistant coating I know of to retain the new look of copper or brass, like on better door knobs. Although, large projects like this would cost much more to coat than it costs to make and ship this. It runs about $100 per square foot..

You could say most of the work we do is custom to order, so below are a few projects we've done that show the diversity of what can be done to solve your needs and desires.  Even if your needs are different than what is shown on these pages, this shows how I'm able to help brainstorm solutions, design, and fabricate nearly anything you may need.

As you'll see most of my client are not local to us, so I do ship orders all across the Nation as well. Don't be shy and write me an e-mail to ask if we can help with your project.

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Client: Moriguchi - 5.5' Wide Mantle 3/17

 

This is a 60" wide copper clad mantle was custom designed and built for Brian & Jodi Moriguchi in Stevenson Ranch, California to be mounted over their natural gas fireplace insert to help shield the heat from their painting just above it. These are the photos I shared with this Client as we worked on this project to help communicate how this was progressing.I had not done much pre-tarnishing of the copper for clients, so this was a bit of an experiment to see what we could achieve in a short time-frame for an interesting look. The cost for this project was $1,467.34 with the crate and freight charges to their home in SoCal.

$1,467.34 delivered to Stevenson Ranch, CA
The size was 5" tall X 60" wide and 9" deep in the center narrowing to 5" on the outside

To see all 23 photos of this fabrication go to:
CBD facebook album

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Client: Rosen - 6' Wide Mantle 11/16

 

This custom indoor 32oz copper covered fireplace mantle piece I made for Ann Rosen. They just wanted a clean smooth look, so they went without the hammering and rivets. The copper has been glued to the wood with an expanding polyurethane glue.

$1,656 delivered to Hartsdale, New York
The size was 5" tall X 72" wide and 10" deep in the center narrowing to 6" on the outside

To see all 20 photos of this fabrication go to:
CBD facebook album

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Client: Varni - 5.5' Wide Mantle 3/16

 

This custom indoor 32oz copper covered fireplace mantle piece I made for Damian Varni in Napa, California. Beside the classy look this is to help minimize the radiating heat from the natural gas fireplace insert below their flat screen TV mounted above.

$1,380 delivered to Napa, CA
The size was 5" tall X 66" wide and 9" deep in the center narrowing to 6" on the outside

To see all 23 photos of this fabrication go to:
CBD facebook album

From: damv@aol.c*m
Subject: I finally got the mantel installed this week
Date: Thu, 20 Oct 2016


Hi David,
I hope that everything is going well up in Oregon. After six months, my finish carpenter finally made it over here this week to install the mantel. I have attached a couple of photos.
My carpenter ended up using two pieces of L shaped heavy gauge steel to mount the mantel. He drilled two holes in the lower part of each L and bolted those to the studs on the sides. The upper part of the L acted as a sort of ledge for the mantel. He cut two grooves in the copper on the back of the mantel, and we just slid the mantel into place. It is not going anywhere.

My wife likes it, and it seems to deflect the fireplace heat as we had hoped which will protect the TV. I might move the television up an inch or two for better spacing, but we will see over the next couple of weeks.

Thanks for making the mantel. It is a nice looking piece.

Damian

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Custom Range Hoods & Mantle Embellishment

Client: Jed Nagel - 62" wide Mantle w/Crown Molding 5/14

 

This custom 32oz copper covered fireplace mantle piece made for a client in Torchlake, Michigan for over their fireplace with larger river rock around it. This was made with a poplar hardwood board inside for support and dent resistance. I also supplied them with SS screws for a sturdy hidden mounting slid sideways.

 

The finished size was 5.5" tall, 10" deep, and  62" wide
Cost
$1,069.65 w/crate & delivery

 

This was made with a thicker looking top shelf board with more over hang out past the crown molding. Hopefully this client will send us shots of this installed.

 

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Client: Rossi - 3' Wide Mantle 3/13

 

This custom outdoor 32oz copper covered fireplace mantle piece I made for Albert Rossi in S. W. Palos Verdes Estates, California. He loved the chimney cap and mantle set I made for a client named Chris & Christine Sarkinen in St. Michael, Minnesota shown below.

$800 delivered to Verdes Estates, CA
The size was 6" tall X 36" wide and 12" deep in the center

To see all 10 photos of this fabrication go to:
http://copper-by-design.com/cc/cp/Rossi.htm#Mantle

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Client: Garvin - 6' wide Mantle w/Crown Molding 12/12

This custom 24oz copper covered fireplace mantle piece I made for Steve Garvin in Hooks, Texas for over their flush mount gas fireplace with a large flat screen TV mounted on the wall over it. He felt it was missing something. This was made with a poplar hardwood board for support and dent resistance and filled the crown molding with a concrete mix. I also made a wall bracket made of a thick 32oz copper to mount on the wall into the studs with SS screws I supplied for an easy sturdy hidden mounting.

 

The size was 72" wide, 8" deep, and 4.25" tall
$575 w/crate, but w/o delivery
(he arranged for his own freight)

 

This can be made with a thicker top shelf board with more over hang out past the crown molding. Even angle cut outwards for a more dramatic look. Hopefully this client will send us shots of this installed.

 

From: From: Steve Garvin <steve.garvin@outlook.c*m>
Subject: Re: Copper mantleCopper fire-pit cover
Date: Mon, 10 Oct
2016


David,
We love our mantle. I will be glad to send you some pictures. David was great to work with and we have received several compliments on the mantle. There was a small mark from shipping but I actually had forgotten about it until David mentioned it. I will set a reminder on my phone to send you some pictures later tonight. We are going to the state fair after work, but I'll get you something when we get home. I'll send some photos showing the mantle close up and some showing it in the room. Is there anything else you would like to see? Thanks! Steve

 

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Client: Zinsmann - 5.75' wide Mantle Cover 8/10

This custom copper fireplace mantle shroud cover I made for a contractor in California for his client for their home. The first image on the left shows the wood structure I made for the copper to be attached to for better dent resistance. The angled copper cover was made in 1 single seamless piece. The straps are merely decorative.

 

$969.60 delivered to Mission Viejo, California
Size:
18" tall X 69" wide and 8" deep in the center

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Custom Range Hoods & Mantle Embellishment

Client: Sarkinen - 3.5' Wide Mantle 7/10

 

This custom outdoor 32oz copper covered fireplace mantle piece I made for a client in Saint Michael, Minnesota for their back yard fireplace he was building. This image shows how they paid me to beat the flat copper sheets up with a hammer to give it this rustic distressed look they were after. This was made with a pair of 2x8 boards cut with this convex curve and covered with 32oz copper with large industrial looking rivets. 2" of the back was covered with stone work, so only 6" in the center showed.

$653.31 delivered to Saint Michael, Minnesota
The size was 6" tall X 42" wide and 8" deep in the center

Our client Chris Sarkinen sent us these photos over a year later (10/11) to show the rustic look of the tarnished copper this has now. He is quite pleased with the results. They also had us make a copper chimney cap for this flue, along with other custom copper pieces.

 

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Client: Yaden - 5' Wide Fake Smoke Exhaust Cover 6/09

This custom copper fireplace mantle shroud cover I made for a contractor in California for his clients who saw one like this at a Disney Land resort and wanted one like it for their home. The first image on the left is his computer rendition. You can see their photo of the actual mantle shroud they wanted me to recreate: http://copper-by-design.com/cw/Yaden.htm

 

$1,209.75 delivered to Danville, California
Size 8" deep X 61" wide bottom, 46.5" tall, and 2" deep X 30" wide at the top

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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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