New Roof Crest: The new cresting was formed in 10′ sections. They were formed in two 3 dimensional faces and soldered together at the entire perimeter.
New roof cresting progress: First round of stamping new roof cresting
New roof cresting progress: Second round of stamping and partial trimming
Closeup detail of finished roof crest
The roof cresting is attached to the ridge covers that we brake formed out of galvanized steel
The original finial was rotted very thin and had numerous patches of tin, caulk, even spray foam!
Where possible original sections are stripped and used to make hammerforms.
A couple of hammerforms and the new components that are made with them
Sometimes we use both male and female hammerforms. Repousse components are hammered out from the behind (female form) then details are chased back in from the front (male form).
This component was too thin and damaged to make a hammerform from so we sculpted a new form
Boxed it up …
Poured a new hammerform (as seen on the top left). This picture shows just some of the modified and custom made tooling for this job
The large “Water Leaf” urn section coming together
Completed, fully soldered zinc finial. All components of this finished finial are hand formed “repousse” and soldered together into one unit. (Repousse is the technique of shaping & hammering malleable metal from the reverse side)
New finial in its place at the end of the new roof cresting
For the historic Loggerhead Key Lighthouse in the Dry Tortuagas National Park we fabricated a new copper roof panel and rib system.
Original lighthouse roof, finial, and spire
We fabricated and installed a new copper finial that is an exact replica of the original including the original vent system. The original “lamp” gave off so much heat that it was necessary to vent the excess heat out through the finial.
We hand formed full relief copper roof cresting consisting of spheres, fleur-de-lis’, and scrolls. These are not just flat sheets with the designs cut out. They are full three-dimensional panels that are 1” thick at their thinnest point and stand proud of the roof a full 6” at the scrolls.
We hand formed copper finials to replicate originals (in the background) as well as restoring existing ones that were salvageable.