Pre-fabricating a metal dormer

Abstract

Pre-fabrication of a metal dormer provides for a one-step and relatively easy installation by a home owner, a roofing contractor or a carpenter. By using an aluminum alloy and specific forming and welding adaptations, a relatively water-tight, light and low-cost dormer may be readily pre-fabricated.

What is claimed is: 
     
         1 . A method of pre-fabricating a dormer, the method comprising:
 forming, by press-brake and according to a planned geometry, a plurality of dormer components from a metal material, the forming creating creases;   cutting the dormer components to fit a roof on which the dormer is to be installed;   spot-welding to form welds between the dormer components;   sealing between the welds; and   filling the creases with filling material.   
     
     
         2 . The method of  claim 1  further comprising etching the metal material to show lines along which the cutting will occur. 
     
     
         3 . The method of  claim 1  wherein the metal material comprises 5083 Aluminum alloy. 
     
     
         4 . The method of  claim 1  wherein the metal material comprises 6061-T6 Aluminum alloy. 
     
     
         5 . The method of  claim 1  wherein the filling material comprises Titanium Putty. 
     
     
         6 . The method of  claim 1  further comprising sanding the filing material. 
     
     
         7 . The method of  claim 1  further comprising anodizing the dormer. 
     
     
         8 . The method of  claim 1  further comprising sandblasting the dormer. 
     
     
         9 . The method of  claim 1  further comprising powder coating the dormer to a desired colour. 
     
     
         10 . The method of  claim 1  wherein the forming creates dimples and the method further comprises filling the dimples with filling material. 
     
     
         11 . The method of  claim 1  wherein the roof has a 9.25:12 pitch. 
     
     
         12 . The method of  claim 1  wherein the roof has a 12:12 pitch. 
     
     
         13 . The method of  claim 1  further comprising etching the dormer. 
     
     
         14 . The method of  claim 1  further comprising anodizing the dormer. 
     
     
         15 . The method of  claim 1  wherein the sealing between the spot-weld locations comprises caulking between the spot-weld locations. 
     
     
         16 . A dormer pre-fabricated by:
 forming, by press-brake and according to a planned geometry, a plurality of dormer components from a metal material, the forming creating creases;   cutting the dormer components to fit a roof on which the dormer is to be installed;   spot-welding to form welds between the dormer components;   sealing between the welds; and   filling the creases with filling material.