Custom Curved Copper Roof Covers Design & Fabrication Page

Updated 3 / 2017

Most all the work we do is very custom to order, but here are some examples of the more custom sheet-metal fabrication we have done to show our versatility of what we are able to offer.  Even if your needs are different than what is shown on these pages, this shows how we are able to help brainstorm solutions, design, and fabricate nearly anything you may need.

These were local projects, but we do ship orders all over the Nation as well, so don't be shy. Write us an e-mail to ask if we can help with your special project. For a large project like shown on this page we may need to build the wood structure to mount the panels on to be sure they would fit just right, and ship the whole assembly ready to install.

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The Chavez Job: 20oz Copper Covered Concave Entry Awning
w/Turret Roof Cap & Finial
Beaverton, Oregon. 2/2014

This was built to cover the front entry. I made the whole wood frame, covered it with layers of 1/4" hardwood plywood, high temp Water & Ice Shield underlayment before the copper went on. It has thick 48oz copper bands screwed on with stainless steel screws, covered with small copper domes to look like large industrial rivets.

The clear cedar tongue and groove soffit was installed after the awning was attached and sealed with tung oil. The scroll work underneath was attached to a clear cedar 4X4. It was also made with 48oz copper with 10ga copper wide wrapped around the connections. These have little if any actual support. They are merely decorative.

Cost: $4,592.40 for this 80" wide awning installed

Follow this link to see all 60 photos from this project:
CBD facebook album

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The Keller Job: 20oz Copper Concave Bay Window Cover
Vancouver, Washington. 3/2012

This was built to cover the existing bay window roof that was around 50 years old. This way there was not the added cost for removing the old copper roof cover, risking water damage in the course of our work, and replacing a lot of the siding that would get damaged in that extraction process, so he saved over $1,500.

I also added 6" eave to this to help better protect the windows below with a copper crown molding over and under this new cover. A cedar frame was made to help support the added eve, then treated with tung oil and attached with 16 deck screws. According to the final weight of 88# w/o the wood frame this cover required about 70.4 sq' of the 20oz copper to form.

This client also wanted to retain this new penny copper look, so he had us buff and lacquer the outside. That added $500 to the cost.

Cost: $3,710 for this 9' 3" wide cover installed

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The Brown/Umberger Job: 20oz Copper Covered Concave Turret
in S. E. Portland, Oregon 2/2012

This was built to cover the electric motor housing protruding up out the roof of their house after installing an elevator inside.

I built and covered this turret with copper. This was built at least twice as strong as house construction; assembled with glue and predrilled holes for the screws. It weighs about 1,500# in all.

Cost: $17k for this 8' wide turret installed

For more detailed description 110 photos and 2 videos for this project click this link:
http://copper-by-design.com/cw/Brown-Umberger.html

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The Edwards Job: 20oz Copper Concave Cupola Roof Cover in Silverton, Or. 11/2011

This was to going be just a 4' wide base for this copper roof covered cupola, but before I began fabrication the client decided they wanted a 7' 3" wide base and were delighted with the results.

I covered this with smooth sheets of copper for a better seal and cleaner look than a standing seam cover you may be use to seeing. This was built at least twice as strong as house construction assembled with glue and predrilled holes for the screws. It weighed about 700#.

Cost: $8,160.40 for this 8' wide cupola installed

There are more detailed description and photos for this project at:
http://copper-by-design.com/cw/Edwards.html

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The Mol/Wilcox Job: 20oz Copper Arched Entryway Cover in N. E. Portland, Or. 2011

This was to be just a simple copper roof cover for a local gutter client, but I suggested using these custom made diamond shaped copper shingles to add some textured character. It cost more than just a smooth copper cover, because it takes a little more copper with all these overlapping seams, but they agreed to give it a go and were delighted with the results.

   

I covered the very top and both lower flat sections with just a single smooth sheet of copper for a better seal. Especially since it would not be seen from the ground anyway.

Cost: $1,917.80 for the 30 sq' of coverage installed

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The Gerber Job: 20oz Copper Arched Entryway Cover & Gutters 2007

This was just a simple roof cover I made for a general contractor: Wes Gerber Better Homes Design and Remodel Inc. 503-481-9332.

After I was done Wes confided with me how Montavilla Sheet Metal quoted $5k to $8k to make this copper cover. I was able to provide this along with the copper gutters and downspouts with assistance installing this cover as well for only $2k.

There are more detailed descriptions and photos for this project at:
http://copper-by-design.com/cw/Gerber.htm

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The Lesh Job: 20oz Copper Arched Entryway Cover, Gutters, & 7' tall Finial Restoration 2006-07

Here is one of our custom copper projects we did at 3565 N. E. 25th in Portland Oregon for a General Contractor named DAW Remodeling Co. rebuilding a house for David Lesh. The first photo shows the new copper, and the next photo shows the aged copper after a couple years when I returned to replace the steel gutters.

 The cost was $3,100 for the 155+ square feet of copper used to cover this arched entry roof.

The cost for the no-clog copper gutter system was $5,974.18.

The cost for the restoration of the 7' finial was $765

The cost for the 3 window well borders was $787.50

There are more detailed descriptions and photos for this project at:
http://copper-by-design.com/cw/Lesh.htm

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The Flagg Job: 20oz Copper Arched Entryway Cover 2006

Here is one of our custom copper roof projects we did at 2703 N. E. 11th in Portland Oregon for our client named Danielle Flagg.

The cost was $2,921 for the 97.5+ square feet of copper used to cover this arched entry roof.

There are more detailed descriptions and photos for this project at:
http://copper-by-design.com/cw/Flagg.htm

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The Yocum Job: 16oz Copper Covered Arched Entryway & Gutters 2002

Here is the copper gutters and awning job we did for Dale Yocum's house that is just above the Metro Zoo, at 4343 S. W. Fairview Blvd. in Portland Oregon.  It was completed in August of 2002. Here is the before and after shots of the back patio area:

Above shows how I had to cut into the siding to fit the awning frame solidly in place, as well as to fit the copper roof flashing up under the siding, so it is sealed from the rain with the finished work and new copper gutters I installed.

There are more detailed descriptions and photos for this project on our fabrication web page at:
http://copper-by-design.com/cw/Yocum1.htm
and the gutter work description web page at:
http://dmr-gutters.com/cg/Yocum.htm

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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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