probably belongs in the home repair section but hey all you need is some flat stock aluminum use a .020 or heavier (readily avaliable at any roofing supply center or sheet metal shop) and a tube of rubberized roof cement along with a caulking gun well of course you will need a hand full of 1/8 alum pop rivets plus a drill motor a 9/64 drill bit a good pair of snips (to cut the piece to size) a pop rivet gun a caulking gun a tube of rubberized roofing cement and a wire brush. Now make sure and allow at least 4 to 6 ins all around the opening. Clean the old metal surface with a wire brush then trail fit the new piece, tap it down around any high spots till it fits nice and flush mark the perimeter with a pencil, now apply a thick coating of the cement from your caulking gun just inside your pencil mark and then make several beads around the opening. Set your new custom fitted piece in place drill and pop rivet on approx 1 in centers around the circumference about 3/4 in from edge of new piece . Seal all pop rivets plus the perimeter edge with your roofing cement and go have a few beers man GOOD WORK

Thank you for the kind comments. Decisiveness and any sort of outcome is better than nothing! I am on a roll! and hope to keep rolling with some other projects. I have tons of painting to do, most of which must wait for the Spring. Palimpsest - I was having the same thoughts. I was considering adding a piece but don't want to make it any taller. I think I'll leave it alone. Arlosmom - I had a great time at the salvage yards. Second Chance is always great, but they have really improved over the years. Some of the warehouses used to be scary - I was always fearful I would be crushed in a roof collapse. It is wonderful to know about their job training programs. They seem to be teaching the young men customer service skills too as I was very pleased with the help I received there. I visited Housewerks for the first time this Fall. It was like a strange dream. After driving thru a desolate part of town, I arrived at that amazing Victorian building with the most strange/beautiful assortment of objects surrounding it. Unbelievable.

Hi - My DH is a commercial roofer with 26 years experience. I'm typing this as he tells me what to pass along as his typing skills are ... First things first. Yes!! You absolutely need to have tapered polyiso insulation added. Without it you're opening yourself up to a lot of problems, not the least of which is the added weight of ponding water on the structure. As for you choice of products, much of it depends of the visibilty of the roof from the ground, upstairs windows etc. Most TPO roofs can look very nice, especially when there are no penetrations to have to flash. The draw back is it is not available to most contractors in less than full roll qty. It also requires the installer to have equipment/knowledge specific to this type of roof. If visibilty of the roof is not a factor, a black EPDM membrane will be very serviceable. EPDM is more readily available in smaller sizes and so should be less costly. Fully adhered would be the best choice. Torchdown, though effective, would be the least desirable IMHO. Playing with that amount of heat on an older structure is just not a good idea when other options are available. We just had an historical structure in our area burn to the ground from this very thing. Sorry this is so long winded. My DH sees a lot of mis-applied roofs and fixes poorly detailed ones all the time. Make sure you choose a reputable firm and insist that you have a Certificate of Insurance proving their insurance coverages.

Christy, Find out from your insurance company if they are tied to a certain manufacturer. they may or may not be, but it's not common practice where I live. That said...if wind is common, then upgrading to a laminated or architectural style shingle may be worth it. 3-tabs are usually rated for 60-mph winds, architectural are at 110-mph winds. Some higher, some lower, but the additional thickness of the architectural shingle does make it a better performer in adverse weather. If you are committed to a certain brand, in this case OC, realize that OC makes both 3-tab and architectural shingles. Again, I've not seen insurance companies that are committed to a certain brand, but I do know that many roofers are committed to a certain brand. So talk to your agent and find out specifically what they will and will not pay for. Upgrading to architectural shingles actually helps them in this case as it'll reduce the likelihood of additional claims in the future. Mongo