Custom Metal Fabrication in Glenwood Springs & Aspen, Colorado

What Is Custom Sheet Metal Fabrication?

Short answer: Custom sheet metal fabrication is the process of cutting, bending and forming sheet metal into parts made to fit a specific building. For homes and businesses, that includes custom roof flashing, chimney caps and crickets, copper gutters, coping caps, drip edge, trim, snow guards and architectural metal accents. Custom-fabricated metal fits tighter, seals better and lasts longer than off-the-shelf parts, especially on mountain roofs.

No two mountain homes are built alike. Timber-frame homes, log cabins, modern ski chalets and historic buildings in the Roaring Fork Valley all have unique rooflines, chimneys and transitions. Stock parts from a big-box store rarely fit those details well, and a poor fit is where leaks, ice damage and rust start.

Rocky Mountain Gutters & Maintenance (RMG) runs its own in-house custom metal fabrication shop in Glenwood Springs, fabricating copper, brass, zinc and steel for homeowners, builders, resorts and other roofing companies across Aspen, Snowmass, Basalt, Carbondale and the Western Slope. Drop off an order for standard custom pieces in the morning and pick it up by mid-day, with no freight delays and no substitutions.

Whether you are a homeowner looking for a copper chimney cap or a roofer who needs custom flashing bent today, this guide covers what our shop makes, which metals hold up best at altitude, and how to place an order.

Why Colorado Mountain Homes Need Custom Roof Flashing and Sheet Metal

Mountain homes need custom sheet metal because heavy snow, ice, freeze-thaw cycles and intense high-altitude sun punish every gap and weak seam. Off-the-shelf flashing and trim come in standard sizes and light gauges. Custom metal is measured and formed for the exact roof pitch, wall angle and chimney size, so it sheds water and holds up under snow load.

Why stock parts often fall short on Colorado mountain properties:

• Unusual roof pitches and angles. Steep roofs, low-slope sections and complex valleys need flashing bent to the exact angle.
• Oversized chimneys and stone masonry. Big stone chimneys need custom counterflashing, crickets and chimney caps that stock parts don't come in.
• Log and timber-frame walls. Round logs and heavy timbers settle and move, which calls for flashing designed to handle that movement.
• Heavy snow and sliding ice. Thin, light-gauge metal bends or tears under snow load. Heavier-gauge custom metal stands up better.
• Freeze-thaw cycles. Water that gets behind poorly fitted trim freezes, expands and pries joints apart.
• High-altitude UV. Intense sun fades cheap coatings and breaks down sealants faster.
• Design goals. High-end mountain homes often call for copper, zinc or color-matched metal that has to be fabricated to order.

Custom Metal Parts We Fabricate In-Shop

Our Glenwood Springs sheet metal shop fabricates custom flashing, chimney caps and crickets, coping and parapet caps, standing seam panels, copper and half-round gutters, copper and brass bay caps and finials, and snow guard systems. Each piece is built from field measurements, templates, shop drawings or architect details.

Browse the shapes we bend on our metal profiles page and the finishes we stock on our metal colors page.

Custom Roof Flashing: Step, Counter, Kick-Out and Valley Flashing

Flashing is the metal that seals the joints where a roof meets a wall, chimney, skylight or another roof plane. We fabricate step flashing, counterflashing, kick-out flashing, headwall and sidewall flashing, valley metal and drip edge, each bent to the actual pitch and angle on your roof. On log and timber-frame homes, flashing is detailed to allow for settling so the seal doesn't tear as the walls move.

Custom Chimney Caps, Chimney Shrouds and Chimney Crickets

Big stone chimneys are common on mountain homes, and they rarely fit a stock chimney cap. We build custom chimney caps and decorative chimney shrouds sized to each flue and chase, in copper or Type 304/316 stainless steel. A chimney cricket, also called a chimney saddle, is a peaked diverter on the uphill side of the chimney that turns water and snow around it instead of letting it pond against the masonry.

Copper Gutters, Half-Round Gutters and Box Gutter Liners

We produce seamless K-style gutters in 5″ and 6″, half-round gutters on brackets, box gutter liners and conductor heads in copper, zinc, steel or aluminum. Copper half-round gutters are a signature detail on high-end Aspen and Snowmass homes, and we match profiles to historic and architectural details. Learn more on our custom gutters page.

Coping Caps, Parapet Caps and Gravel Stops

Flat and low-slope roofs on commercial buildings, multi-family projects and modern mountain homes need metal on top of every wall and at every roof edge. We fabricate coping caps, parapet caps and gravel stops to the wall widths and lengths on your drawings, using profiles from our shop's own profile library.

Standing Seam Panels, Metal Siding and Trim

Our shop fabricates standing seam panels for roofs and walls, metal siding and accent walls, along with matching drip edge, siding trim and finish pieces in Kynar 500 colors. Metal roofing and siding are also a fire-resistant choice for homes near the wildland-urban interface.

Copper and Brass Bay Caps, Finials and Architectural Accents

Copper bay window roofs, turret caps, finials and brass trim are some of the most requested pieces in our shop. We fabricate them from 16, 20 or 24 oz copper, sheet brass or pre-weathered zinc. When the spec calls for 20 oz copper, that's what gets installed. See more specialty roofing work.

Snow Guards, Snow Fence and Ice Control

Steep metal roofs shed snow fast, and a sliding snow load can damage gutters, decks and anything parked below. We fabricate and install snow guard and snow fence systems designed for actual Roaring Fork snow loads. RMG is also an authorized Thermaline installer for engineered roof edge panels that help stop ice dams. Learn more about snow and ice control.

A Same-Day Sheet Metal Shop for Roofing Companies and Contractors

Roofing companies, builders and contractors across the Western Slope use RMG as their local sheet metal shop for custom flashing, trim, coping and copper work, with same-day turnaround on standard custom pieces and no minimum order.

When a field measurement changes mid-job, waiting on an out-of-state supplier can stall a crew for days. Our shop is in Glenwood Springs, so you can bring specs in the morning and have finished pieces by mid-day while your crew is still on site.

What area roofers and contractors order most:

• Custom flashing and trim bent to your profile, gauge and color
• Drip edge, valley metal, counterflashing and kick-out flashing
• Coping caps, parapet caps and gravel stops for commercial and low-slope roofs
• Copper, brass and zinc details your crew doesn't stock
• Shop drawings and submittals for general contractor and architect approval

What to Include With a Shop Order

A complete order helps the shop get your pieces right the first time:

• A profile sketch or drawing with every dimension and bend angle
• Metal type and gauge or ounce weight, for example 20 oz copper or Kynar-coated steel
• The color name from our metal colors page
• Piece lengths and quantities
• Hems, end details and any notes on how the piece will be installed

Best Metals for Custom Fabrication in the Mountains

The best metals for custom architectural sheet metal in the mountains are copper, brass, zinc, Kynar-coated architectural steel, aluminum, Galvalume and stainless steel. Copper, brass and zinc offer long life and a natural patina for high-end homes. Kynar 500 (PVDF) coated steel is strong and color-stable under high-altitude sun. Aluminum is light and rust-proof, and stainless steel stands up to chimney heat and exhaust.

Avoiding Galvanic Corrosion

When two different metals touch in the presence of water, one can corrode the other. This is called galvanic corrosion. For example, copper runoff onto aluminum or galvanized steel can cause early failure. An experienced metal fabricator matches compatible metals and fasteners so every piece lasts.

How to Order Custom Metal Fabrication From RMG

There are two ways to work with RMG's metal shop: a full-service project where we measure, fabricate and install, or a same-day shop order where you drop off specs in the morning and pick up finished parts by mid-day. Homeowners usually choose full service. Builders, contractors and other roofers often use same-day shop orders.

Full-Service Custom Metal Projects

• Field measurement and templates. We measure the roof, chimney, walls or trim on site and make templates for complex shapes.
• Design and material selection. We help choose the metal, weight or gauge, color and profile, or work directly from your architect's details.
• Shop fabrication. Our Glenwood Springs shop cuts, bends, solders and finishes each piece to spec.
• Installation. Our own roofing crews install the metal and integrate it with the roof, gutters and snow systems.

Same-Day Shop Orders

• Bring your order. Drop off specs, drawings or field measurements in the morning.
• We fabricate it. The shop confirms materials and forms your pieces in copper, brass, zinc or steel.
• Pick up same day. Standard custom pieces are ready by mid-day, with no overnight freight and no waiting on an out-of-state supplier.

Because the shop is local, a changed field measurement doesn't stall the job. A new piece can be formed the same day.

Signs Your Roof Flashing or Chimney Cap Needs Replacing

Failed flashing is one of the most common causes of roof leaks. Watch for rust, loose or lifted metal, cracked sealant, and water stains near chimneys, skylights and walls. Replacing worn flashing with custom-fabricated metal stops leaks at the source instead of patching them with caulk.

Replace, Don't Just Patch

Caulk and roofing tar are short-term fixes. In freeze-thaw climates, sealants crack and pull away within a season or two. Removing failed flashing and installing properly lapped, custom-formed metal is the long-term solution. RMG's roof leak repair team can track down the source of a leak and fabricate the exact replacement piece.

Architectural Sheet Metal for Resorts, Commercial Builds and Architects

Beyond homes and area roofers, our shop handles architectural sheet metal at a larger scale:

• Resorts and hotels: large-format facade panels, parapet caps and architectural sheet metal at resort scale
• Commercial and multi-family: standing seam panels, parapet caps and commercial gutters fabricated at scale
• Builders and general contractors: shop drawings, submittals and same-day custom parts so crews never wait on a flashing detail
• Architects: fabrication directly from architect details for multi-million-dollar custom builds

On a custom home, downtime is one of the most expensive parts of the job. A local shop with stocked copper, brass and zinc keeps the schedule moving. Visit our commercial roofing page to learn more.

Custom Metal Fabrication Across the Roaring Fork Valley and Western Slope

Our sheet metal shop is at 318 20th St in Glenwood Springs, and we fabricate and install custom metal for homes and businesses in Aspen, Snowmass, Basalt, Carbondale, Glenwood Springs, New Castle, Silt, Rifle, Eagle and Vail. RMG has served the Roaring Fork Valley since 1990.

Custom Metal Fabrication FAQ

Where can I get custom flashing made near Aspen or Glenwood Springs?

RMG's in-house shop at 318 20th St in Glenwood Springs fabricates custom flashing, trim, coping and chimney caps for homeowners, builders and roofers throughout the Roaring Fork Valley. Standard custom pieces dropped off in the morning are ready by mid-day.

Do you fabricate custom metal for other roofing contractors?

Yes. RMG is the shop other roofing companies use, with no minimum order. We also provide shop drawings and submittals for builders and architects.

What is the difference between custom and stock flashing?

Stock flashing comes in standard sizes and light gauges. Custom flashing is measured and bent to fit your exact roof pitch, wall angle or chimney, so it seals better and lasts longer.

What is a chimney cricket, and do I need one?

A chimney cricket, or saddle, is a peaked diverter built on the uphill side of a chimney. It steers water and snow around the chimney so it can't pond against the masonry. The International Residential Code generally requires one on chimneys more than 30 inches wide across the slope, and on heavy-snow mountain roofs it's a smart addition even on smaller chimneys.

What is kick-out flashing?

Kick-out flashing is a small angled piece at the bottom of a roof-to-wall joint. It sends water into the gutter instead of down the face of the wall. A missing kick-out is a common cause of rotted siding and sheathing.

How long do copper chimney caps and gutters last?

Copper is one of the longest-lasting roofing metals. With proper installation, copper chimney caps and copper gutters can last for many decades, developing a natural green-brown patina over time.

How long does copper take to patina in Colorado?

Copper darkens to brown within months. The green patina can take many years to form in Colorado's dry climate, and it varies with sun, moisture and exposure.

Is custom metal fabrication expensive?

Cost depends on the metal, gauge, size and complexity of each piece. Custom metal often costs more upfront than stock parts, but it lasts longer and prevents costly leaks and repairs.

Can you match the color of my existing metal roof?

In most cases, yes. RMG stocks Kynar finishes, metallics, wood grains and bare mill metals. See real swatch photos on our metal colors page.

How fast can custom metal parts be made?

For standard custom pieces, RMG offers same-day turnaround: drop off your order in the morning and pick it up by mid-day. Larger or more complex projects are scheduled with you.

Get a Custom Metal Fabrication Quote

From a single copper chimney cap to a full set of half-round gutters, coping and architectural trim, custom sheet metal fabrication protects your property and finishes it with a look that fits the mountains.

Schedule your free, no-obligation custom metal fabrication estimate today. Call Rocky Mountain Gutters & Maintenance at 970-945-8048, visit our shop at 318 20th St in Glenwood Springs, or request a free estimate online. Roofers and contractors can call ahead with a shop order for same-day pickup.

Related reading: Snow Guards for Metal Roofs · Ice Dams in the Roaring Fork Valley · WUI Home Hardening in Colorado's Mountain Region · Metal Fabrication

This article is for general education. Material performance varies with installation, exposure and local conditions.