Unique, One of a Kind Custom Copper and Aluminum Sheet Metal Design/Fabrication Photo Page

 Updated 2 / 2024

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Even though most of the work I do is custom work, here are a few projects I've done that show the diversity of what I do to solve your needs and desires.  Below are links to larger photos and whole web pages with more detail about the more unique custom sheet metal projects I've done.  Even if your needs are different than what is shown on these pages this shows how I'm good at helping to brainstorm solutions, design, and fabricate nearly anything you may need.

These days most of my client are not local to us, so we 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 unique needs.

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Click on any of these photos to see more photos of these unusual items and read about those projects or see a larger copy of the same photo for a better look at the details.

7th Year 'Copper' Anniversary Gift Frame

I was asked to make this copper picture frame for their 7th year anniversary gift (copper), so he could surprise his Sweetie with it in time. He also wanted it engraved at the bottom with the phrase: 'L.O.V.E. never fails', that had special meaning for them.

He had a large black & white digital photo they liked from their wedding day, so I did some image editing to give this a little color to enhance the image. I added a sepia tone and colored in the bouquet. He liked what I did and had me order a large print of this on an aluminum sheet to fit in this copper frame.

The outside frame is 4.5" thick and measures 28" X 38" outside, with an inside measure of 19" X 29" plus a small 1/2" recess.

The cost was:
$377.80 for the 20" X 30" print on aluminum
+ $495 for the 11 sq' of 20oz copper frame
+ $200 for the engraving
= $1,072.80 total cost

He is local, so no freight charges apply.

The engraving was done by: Rich Hawthorne.


Award

I was asked to make this award for a Client in Orlando, Florida. It is formed with 32oz copper made 12" wide X 11" tall and 4" deep. I had a local guy do the engraving with his sandblaster, make the wood base, and lacquer it. This is the same guy: Rich Hawthorne who help make my logo plaque.

With overnight freight this cost them $685 delivered.


This is a copper sewing machine headstone for our client Chris Freybler of Custom Engraving, who had made the name plaque. Their Ph# 616-878-5644 in Byron Center, Michigan. This was built for one of their clients.

This was a small headstone with the base of just 18" X 18" X 2" tall. The sewing machine table is 8" wide. The legs are made with a thick 48oz copper for strength. I had located a molded resin figure for the sewing machine that I covered with a thin 12oz copper and hammered it over the form to show the shape and detail you see here. The silver looking plate on the left side of this sewing machine is stainless steel.

copper sewing machine headstonecopper sewing machine headstone

I had quoted this for just $450 delivered to Byron Center, Michigan 9/10

Although, for as much time this took to get the level of detail I had terribly undersold myself for this small project. If I had charged 4X more I still would not have made enough to cover all the time I spent on this, but it was an interesting project to do that shows of our creativity.

Metal Face Mask

My Apprentice Chris Freedman & I designed and built this original metal face mask for a client with the stage name 'OD', who is a rapper located in Bossier, Louisiana. He ordered this to wear during his musical performances. It was made with 24oz copper sheet metal. We only charge $400 for this mask with shipping, even though it took us more than a hundred hours to design and build this after exchanging 37 e-mails and many digital images of the cardboard and aluminum mock-ups Chris had made. It was an interesting project, but not very profitable. Quite a departure from replacing gutters or building copper chimney caps we normally do.

It has a separate jaw piece that is designed to move up and down with his jaw. There are no teeth in the middle to allow for his mic to be very close to his lips.


Although, for as much time this took to get the level of detail I had terribly undersold this small project. If I had charged 4X more I still would not have made enough to cover all the time I spent on this, but it was an interesting project to do that shows of our creativity.

$400 w/shipping to Bossier, Louisiana

Follow this link to see a video of the jaw in action
http://www.youtube.com/watch?v=2_jB02o540E

This is 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

Whole Cupolas

Client: Edwards in Silverton, Oregon 11/11

This project was 7' wide ISD, Roof was 7' 10" wide. The sides were covered in aluminum sheet metal, and the roof was clad w/20oz copperas seamlessly as possible. This structure was built 2X stronger than standard house construction.

Cost: $8,160 w/enhanced rooster style weathervane, delivered, and installed

Client: Bardana in Lake Oswego, Oregon
20oz copper clad cupola for their gazebo we also covered with copper 1/11

This is a custom classic cupola that we made for a local client. It is 4' wide at the base and the roof is 5' wide for a 6" eave. The roof is designed to the same 6/12 roof pitch as the gazebo.

This cupola was built with 56 separate 2x4 boards that were angle cut, glued, and held together with screws. There are no nails. The eaves were made with 8 - 2x6 boards. There are 83 wood pieces to this cupola you see here. It is strong enough I am certain it could handle well over 2,000# set on top of it.

We also covered their entire 11' wide gazebo roof with new plywood and 20oz copper after stripping off the rotten wood shakes.

Cost: $7,500 installed

Client: Svenson - arrow style weathervane w/full size crow over this large turret roof cap 1/11

This was a custom classic 3 tail feather arrow shaped weathervane with a life size 3-D crow figure perched on the shaft made in 32oz copper for a client in Chautauqua, New York to set over the 42" wide turret roof cap made in 20oz copper.

$2,775 - w/crate & shipping to New York
Weathervane alone was $1,200 w/o shipping

Client: Ueber - Vent Cover 8/10

This was a custom wood concave stove vent range hood I covered in copper for a client in Vancouver, Washington who wanted this rustic industrial look. The first image on the left is before the decorative straps were attached. It was made with few seams. You can see more photos and detailed description of this on this separate web page:
http://copper-by-design.com/cw/Ueber.htm

$1,085.30 - local client pick-up here at my shop

Client: Zinsmann - 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

Client: Sarkinen - Mantle 7/10

This custom copper fireplace mantle piece I made for a client in Saint Michael, Minnesota for 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 look they were after. This was made with a pair of 2x8 boards cut with this convex curve and covered with 32oz copper. The size was 6" tall X 42" wide and 8" deep in the center, but 2" of the back will be covered with stone.

 

$653.31 delivered to Saint Michael, Minnesota

Here's a trough they also had me make to resemble a photo of an old rusty steel one

Cost: $280 delivered to Saint Michael, Minnesota w/ a chimney cap
($128 less than the actual copper weight)

Client: Yaden - 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

Client: Yaden - Fake Dormer Vents 6/09

This was a set of 4 custom copper louvered dormer vents. 3 were made to be just 5' wide and the large one was 8' wide. The were made to fit a 7/12 pitch roof. The first image on the left shows the solid copper back, but I would normally have a stainless steel screen there, but they just wanted these sealed off for aesthetic use only. You can see more photos here: http://copper-by-design.com/cw/Isa.htm

Cost: $3,725 delivered to Birmingham, Alabama

Client: Fields - Vent Cover 3/08

This was just a simple custom copper cover for above this copper range hood I made for a client who wanted a good way to cover this unsightly exhaust flex pipe that ran up through the ceiling. The lower half was made by another shop. The upper cover was made all in one piece with no seams and they report it fit like a glove.

$437.50 delivered to Cave Creek, Arizona

Client: Matovich - Lighted Cupola w/Weathervane Mount 3/08

This is a matching lighted cupola to a set of chimney caps made in my Tuscany arch style for Scott Matovich in Setauket, New York. He wanted a weathervane mount built into the roof of this as well. I made a taller base to sit on the roof ridge. I had to be creative to work out a nice soft glow inside, and rig up the security flood light in the base. You can see more photos at:
http://copper-by-design.com/cc/cp/Matovich.htm#Cupola

I experimented with several  different systems to see what would work best. I ended up using a set of 2 bulbs that reflected off a shield above and a larger reflector below in the base. I also made a third white reflector up in the center of the cupola. This project took me longer to build than their larger chimney cap.

Total cost: $2,378.75 w/crate & shipping to New York

Client: Werner - Entry Door Decorations 4/07


This is an entry door with copper sheet-metal accents on the lower part of the door and door frame, as well as the thresh-hold.

Copper Counter Tops

Standard and Security Mailboxes

Client: Lesh - 7' Tall Copper Finial over 3/4" Marine Grade Plywood, Orb Filled w/Concrete, along w/Copper Covered Cedar Window Well  Frames 5/07

Cost: $1,552.50 - Portland, Oregon

Client: Yocum - Exterior Copper Bench Top over Ipe Hardwood set over the Brick Wall around Window Well I also built 8/02

Cost: $865 - Portland, Oregon

Water Features

Custom Window Trim Flashing

Roof Flashing Pipe Jacks

12/12 pitch 5.25" inside X 18"+ tall

Screened Louvered Vents for over Roofs, or in Siding, and Chimney Flashing Kits

 Copper Trim Work

Forest Grove, Oregon

Roof Flashing Rain Diverter

West Linn, Oregon

Aluminum Roof Beam Covers

Milwaukie, Oregon

Aluminum Fascia Metal over Birch Plywood

Wall Cap Metal

Vancouver, Washington

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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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custom sheet metal fabrication

 

custom sheet metal fabrication

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custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

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