What's Inside
The SafeStax Sheet Metal Product Fabrication Guide is a comprehensive training manual covering every product in the chimney cap line — from basic flat caps to advanced hip & ridge systems and chase covers.
9 Manufacturing Sections
| Section | Product | Difficulty |
|---|---|---|
| 7.1 | Flat Skirt Assembly | ⭐⭐ Intermediate |
| 7.2 | Angled Skirt Assembly | ⭐⭐ Intermediate |
| 7.3 | Standard Flat Cap | ⭐ Basic |
| 7.4 | Traditional Flat Cap | ⭐⭐ Intermediate |
| 7.5 | Standard Hip & Ridge | ⭐⭐⭐ Advanced |
| 7.6 | Traditional Hip & Ridge | ⭐⭐⭐ Advanced |
| 7.7 | Beaded Collar Chase Cover | ⭐⭐ Intermediate |
| 7.8 | Formed Collar Chase Cover | ⭐⭐⭐ Advanced |
| 7.9 | Basic No-Hole Chase Cover | ⭐ Basic |
The Bridge System
SafeStax's core innovation — a complete workflow from field measurements to finished product:
- Field measurement protocols (Section 6)
- Parameter entry into Fusion 360 parametric files (97–122 parameters per file)
- Automated manufacturing file generation
- 10-station production tracking from Design → Plasma → Bending → Assembly → Quality
Change 4 Numbers, Get a Perfect Cap
The parametric system handles 97–122 parameters per file with 0.001° tolerance. When Jeffrey improves the files, every partner gets the update automatically.
Code Compliance Built In
Every product meets or exceeds industry standards with automated verification:
- NFPA 211 compliance — automated checking
- IRC R1003.9 requirements — built into every design
- Step-out logic for non-compliant situations
- Professional standards with legal compliance at every step
Material Specifications
Standardized on Englert Color Clad — 4'×10' sheets, 24-gauge, 40+ year warranty. 40+ color options. Complete cost structure from $86.43/sheet baseline with fabricator vs. customer pricing breakdowns.
Complete Bills of Materials
Every product section includes a detailed BOM with exact component counts, rivet quantities, hardware specifications, and material costs. No guessing — you know your real costs before you start.
Step-by-Step Assembly with Jig Instructions
- Bending instructions for every component
- Assembly sequences with rivet placement rules
- Jig-based assembly methods (recommended) and basic no-jig methods
- Jig designs refined over 22 iterations
- Glossary of trade-reference terminology