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100 YEAR R O O F ? Seamless Corner for chimneys and other locations where even a pinhole is not acceptable.
CORNER FLEX Chimney and other uses on corners where a solid one piece flashing is needed. https://www.amazon.com/Amerimax-Home-Products-CornerFlex-Flashing/dp/B000DZGHOK Walmart also has a version of this.
A solid PERFECT CORNER 1 piece without pinhole:
You can make your own PERFECT CORNER w/o Pinhole, higher and wider by taking a piece of Aluminum or copper or other flashing and fold it like a Japanese fan (many folds over each other, then fold it 90 deg and then expand it around the corner ; the outer ends will expand most while the closest to corner folds will expand the least).. hope this helps. Look at the pic below, then imagine taking a piece of AL flashing and putting it flat then fold it over and over on itself in perhaps 1/4" increments to make it as wide and as tall as you need, then fold it 90 deg vertically, then fold it again around the corner 90 deg the other way,,, see how the outside edge spreads the most to go around the "impossible" corner, now you have a 1 piece NO LEAK NO PINHOLE corner flashing. In fact you could make the whole chimney flashing sides top bottom and corners like this as one long wrap around the chimney piece for EZ installation on high pitch dangerous roofs where speed is critical to avoid exhaustion (yeah it gets tiring and hot very quickly when you have to spend 90% of your time and energy just staying up there. ). ADVICE: get a side cutter tool with concrete cutting wheel (4" wheel is more than enough), then cut a shallow 1/2" to no more than 3/4" cut once you have the flashing in place (bend over the last 1/2" of the flashing to form a lip ) cut a slot to exactly fit the "lip": put urethane caulk in the slot and then tap in the "lip" into the slot with a hammer, this will not leak ! ! This is part of the 100 year roof design, the other part of the 100 year roof design is the seamless metal so that not one screw is exposed to the rain at least from vertical direction; put any necessary screws ON TOP of any seams, NEVER in the valley of the metal roof panels. (why put a screw at the bottom of a river ? ) Wise ! Overlap everything as much as possible to avoid sideways rains from leaching back up under roof and flashings. Urethane every seam with at least 2 beads for double protection. Paint any screw heads and espec any exposed rubber or neoprene type washers to prevent them from drying out and cracking which would become a leak point. Use the widest roof gable peak they sell for more protection and make sure the roof closure foam is in place to prevent sideways rain intrusion. ELiminate any roof thru issues to make a quicker easier installation IE Put drain vent pipes elbowed with PVC around the side of the eave and then up, starp down with metal strap, this eliminates you having to do tedious vent boots and lots of exposed screws which eventually will leak. Take out roof mounted vents to make it EZ, then use side mounted on the ends of the attic fans or other vents. Remember you do NOT have to take off the old roofing to install metal, SO you get actually more insulation and your attic will be cooler anyway, lowers electric bill too. IMHO ; metal roof built this way will be nearly maintenance free for perhaps 100 years. if you occasionally inspect for loose anything (should be very rare). This 100 year design asks you also under flash in the olf fashioned way the area around chimneys and any other projections coming out of roof.
So the real key is do the OVER & UNDER method so you get the advantage of a double coverage in the case where something may become deteriorated or damaged, you still got a leak proof chimney area. https://www.amazon.com/Amerimax-Home-Products-CornerFlex-Flashing/dp/B000DZGHOK
2. A Near Perfect Alternate method: ( https://youtu.be/xq2qTVUyIL8 is a link for an alternate "near perfect" corner but it will still have a pinhole at the very intersection corner where all 3 planes meet ) GREAT VIDEO AND METHOD; But I had to realize that it was a double layer sheet folded in half , and the folded half is on the top when he starts. it worked with paper, it also still has a tiny pinhole where water "could " get in the corner, but that could be urethane caulked in the pinhole corner. Could do this as well in copper, or aluminum, or other non corrosive rust proof flashing material that was thin enough to bend easily. DO NOT BEND MORE THAN 1 X each as it will weaken the metal and create a leak.
Welcome...to the Ugly Underbelly of the Rigged ROOFING Industry ; build a 100 year roof !
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