Great project! Where did you find the flashing to put on top of the exposed beams, that stuff has my number...
I made it myself.
The lumber store was selling 5" x 8" (and 8" x 12") flat sheet metal flashing "shingles". I simply cut them to side, bent them, and folded them up. I think I had posted photos of the "process" before, if not, click the links below to see pictures.
1. Cut sheet to size + notches
Drew some lines on the flashing with a speed square and pencil. Cut the flashing to a 3 1/2" wide width (1" return on each side + 1 1/2" wide for the rafter width). Then cut the notches into it where it will be folded.
2. Fold in vice
I lined the jaws of my bench vice with masking tape to keep from scratching the flashing finish, then bent the flashing along the pencil lines. There's no need to clamp the sheet metal in the vice, just get the jaws close together, maybe 1/16" apart. Then slip in the sheet metal and fold over using a straight edge as an assist. I used my speed square, worked great.
3. Flashing sides folded over
This is what the flashing cap looked like with the sides folded over but before bending it to 90 deg.
4. Final bend
This was the final 90 deg bend to the flashing. After this I'd squeeze in the sides a bit more so that it would fit tight and snug over the end of the 2x rafter framing. Over time I found it helpful to wait to do the last 90 deg bend until I actually needed to install the flashing. It allowed me to stack all the folded flashing caps within each other.
Drew some lines on the flashing with a speed square and pencil. Cut the flashing to a 3 1/2" wide width (1" return on each side + 1 1/2" wide for the rafter width). Then cut the notches into it where it will be folded.
2. Fold in vice
I lined the jaws of my bench vice with masking tape to keep from scratching the flashing finish, then bent the flashing along the pencil lines. There's no need to clamp the sheet metal in the vice, just get the jaws close together, maybe 1/16" apart. Then slip in the sheet metal and fold over using a straight edge as an assist. I used my speed square, worked great.
3. Flashing sides folded over
This is what the flashing cap looked like with the sides folded over but before bending it to 90 deg.
4. Final bend
This was the final 90 deg bend to the flashing. After this I'd squeeze in the sides a bit more so that it would fit tight and snug over the end of the 2x rafter framing. Over time I found it helpful to wait to do the last 90 deg bend until I actually needed to install the flashing. It allowed me to stack all the folded flashing caps within each other.
Also, I found it significantly easier to nail on the flashing (using 3d galvanized nails) with the rafters on the ground or saw horses. Much easier than trying to install them after the rafters were nailed in place (not being up on a ladder and not having the end of the rafter boing around on you). It did mean being a little more careful lifting the rafters up into place so that I didn't bang the flashed ends into anything. . . mostly so I wouldn't have an ugly dent in the flashing cap.
It's not a speedy process, but I think I got it down to 3-4 minute average per end cap. Now, multiply that out by the 48 end caps I needed total on this project and it's a fair amount of time just bending / cutting sheet metal. I didn't do it in one shot, though. Mostly in the week or to leading up to when I'd need them I'd do a certain number each night. Or do all the initial cuts one night, then bending the next night. And I did them in the evenings after dark. It was either that or sit on the couch and watch TV.
Also, if you need to make your own flashing profiles, I found this very cool video on how to make your own break or extrusion die. Very simple to do out of a piece of plywood.
Flashing extrusion die.
After thinking about this a bit more, if you found the right width of roll flashing, you could probably save a whole mess of time by setting up a jig / die to extrude the "U" shape for the flashing caps (that's where I burned up a lot of time, that and marking out the fold lines with pencil). Then you can extrude an entire roll in no time, then simply snip them to size and be done with it. Dang, I wish I had thought of that, now that I'm mentioning it here.
As Dad used to say: "old too soon, smart too late."
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