How to make a custom copper roof vent

August 17, 2009

I’ve had a bunch of people ask me how I made the copper vent in the last post. I had to make a smaller one for the the master bath steam shower; so I took pictures along the way.

Make a tube: single lock a copper sheet into your desired diameter and length. You should remember geometry from junior high but if you don’t; multiply your desired opening by 3.14, that will be the size of your flat stock before you roll it. Since the vent tube will be in the weather make sure you solder the back seam. This one is a six inches across.

Make a ring: the protection ring will keep out wind driven rain. The outer ring should be about 2.5″ wider than the vent pipe you just made. Same as the other pipe; single lock and solder the seam.

Roll a few beads into the copper; it adds strength and beauty to the job.

Fabricate three struts to support the outer ring, these can be riveted on. Don’t forget to turn down all of your free edges; you want a place for water to drop off before it reaches the inner vent pipe. I test each vent I make, and I have forgotten to turn down the tabs, it leaks, trust me.

Rivet the outer ring to the struts, use two rivets per strut and the whole assembly will be rock solid. Also use copper rivets with BRASS mandrels; don’t use the phony copper rivets with steel mandrels; after the rivets are set the head of the mandrel stays behind. When it gets wet it will rust and leave streaks on your beautiful new vent. Spend a couple extra bucks and get the right rivets.

Make a cone: the cone should be at least 2″ wider than the inner vent pipe. Rivet the seam and solder.

When you make the cone be sure to leave three tabs to rivet the cap to the three struts.

Ready to be brought to the job site. This vent is completely baffled; meaning it won’t leak during heavy wind driven rain or snow. Since it is made from copper it should last at least 100 years.