How to Repair Holes in Metal - Video 1 of 3

In today's video I will be showing you how to repair a rather large hole in a cast iron gutter. This is the first of three videos on repairing metal.

TODAY'S TOOLKIT

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I'm currently repairing and renovating the cast iron gutters on my old cottage. Today's repair is to a badly rusted 90 degree corner section, where the gutter had completely rusted through.

I bought some Isopon P38 and Isopon P40. The P40 is a fibre glass reinforced filler and so is great for spanning holes. The P38 is a multi-purpose filler which is typically applied on top of the P40 to fill the minor holes and dents.

With the Isopon P40 applied and set, I sanded it lightly with my Black & Decker power file sander. I then applied a thin coat of P38, and once set, sanded this with a 120 grit sand paper.

I then primed the section of gutter with Bonda Rust Primer, and then applied a top coat of Johnstone's Stormshield Gloss.

So that's a large hole fixed. Stay tuned for next week's video where I'll be fixing a smaller hole with Milliput epoxy putty, and then finally glueing a section of gutter back together with JB Weld Epoxy adhesive.

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LET'S CONNECT!
Charlie DIYte

[azza]

Another great video Charlie, this is the kind of content i enjoy watching not “how i price jobs” or “test tuesdays” etc but how to carryout the work

[leckyman]

Hi Chalie, glad to see you restire these old gutters to keep the authenticity of the house .

[mikes]

Thanks for posting it’s been some years since I had to work with cast iron but your tips, as usual, just show how none complex and straightforward repairs can be. 👍🏻👍🏻👍🏻 saving pounds 💷

[valborchardt]

Thank you dear, really great tip you have. Enjoyed watching. Take care, from South Africa

[tormenting]

Really like your videos. Just wanted to say thank you for all you do.

Best video hands down was the blum hinges! Helped me so much

[stevestevelinkbtinternetcom]

Metal garage door sill repair, here I come! I’ll give the stuff I used for car repairs another try!

[spinynorman]

I will be tackling a cast iron gutter now Charlie, you are amazing, thanks:-)

[AHMADKAMALZUBER]

Perfect...i shall try it at my gate . Never thought there is a fiber glass solution to a metal hole. Thank you

[kerryfoster]

P38. Amazing stuff goes rock hard and sticks to anything. Strong and durable. You have to work very quick though. Love it!

[mgarcia]

Very informative and helpful video. Thanks so much, Charlie!

[Chris-pvht]

Nice Job Charlie. My cast iron guttering wasnt as bad as yours when I moved house but did have some leaks between joints. I fixed it up and painted guttering inside a couple of times over years with bitumen paint. On outside I used rust remover, hammerite black paint. Then later grey undercoated and International 10 year gloss paint so far 8 years on its kept its colour very black. I have one of them B&D electric files too blooming good tool it is but it can be quite vicious

[ivangreat]

Nice work Charlie, looking good for winter

[philipjones]

Thanks for taking the time to share your knowledge with us 👍

[earthenergyhex]

that gutter turned out great, nice work

[Kayyyman]

a flap disc (or non-woven for fragile materials) is a good one to remove rust and paint for your next one!

[WoodworkingBrewer]

Just to let you know Charlie the bitumen is absolutely fab, I’ve used it on the outside of our house ( which is a wooden barn.) It does a great job of repelling water, I would highly recommend .

[paulamv]

Great video charie thanks for sharing.

[mrv]

do u know if u can use the P38 body filler to surface fill on wood instead of using 2 part wood filler???

[WelshRabbit]

Eeeek! I'd take a different route. Cast iron for rain gutters always struck me as incredible overkill. Unless I'm doing a bona fide historic preservation/restoration type project, my strong temptation is to take all the cast iron down and send it off to the metal recycler and replace with suitable seamless extruded PVC gutters. Anyway, you did a great job. Thanks for posting

[amyyates]

Thanks for that. We are going to use these tips to repair a hole in our car port. We have tried some metal tape (Byute Flashing) but water still gets through.