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.
You can buy me a coffee here www.buymeacoffee.com/charlied... or become a monthly member to unlock Discord forum membership, exclusive content and automatic entry into my FREE Monthly Giveaway. Thank you SO SO much!!
You can now access my 🛠Charlie DIYte Amazon Tool Store here www.amazon.co.uk/shop/charlie... - where you'll find all my tried, tested and much loved DIY tools arranged into handy categories.
TODAY'S TOOLKIT
- Bosch Professional GWS Angle Grinder geni.us/Doyqhw (Amazon)
- Isopon P38 Multi-Purpose Body Filler bit.ly/2z5iJlm £9
- Isopon P40 Body Filler for Holes (fibre glass reinforced) bit.ly/2SmEzJX £15
- Black & Decker KA900E Power Sander geni.us/pNcKANn (Amazon)
- 120 grit sand paper 5m bit.ly/2Q0bfYa £10.39
- Hamilton Prestige 4pce Filling Kife set geni.us/8OZhYaS (Amazon)
- CT1 Multi Solve Spray geni.us/oKGF (Amazon)
As an Amazon Associate I earn from qualifying purchases.
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 actually bought a new replacement section from Gutter Supplies bit.ly/2ELm6E9 but I couldn't use it as the collar was too close to the corner section, so I had to resort to plan B - of filling the hole and repairing the corner section of my existing gutter.
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.
SUBSCRIBE - you can subscribe to my Channel here:
/ charliediyte
LET'S CONNECT!
Charlie DIYte
-- Email: [e-mail]
-- / charliediyte
-- charliediyte.co.uk/
-- / charliediyte
-- / charliediyte

[@azza1793]

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

[@stevestevelinkbtinternetcom]

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

[@mikes6844]

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 💷

[@mgarcia2445]

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

[@tormenting360]

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

[@CharlieDIYte]

Thanks mate - that means a lot! I tell you, I wouldn't still be doing this without people like you taking the time to comment!

[@leckyman2010]

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

[@CharlieDIYte]

Yep, was hoping to do another section this summer but got none more refurbished, which is frustrating. Hope they last another winter. The Bonda Rust Primer is awesome though. They look as good as new one year down the line.

[@spinynorman8217]

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

[@philipjones9297]

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

[@CharlieDIYte]

You're welcome, Philip - thank YOU for taking the time to comment!

[@CharlieDIYte]

🛠Charlie DIYte Amazon Tool Store amzn.to/3fcLnY4 - all my tried, tested and much loved DIY tools. You can help support me by Buying me a Coffee ☕ bit.ly/3xuQ3zb or by becoming a Member to unlock a host of benefits - thanks so much 🙏.

[@ivangreat133]

Nice work Charlie, looking good for winter

[@CharlieDIYte]

Thanks! It's only a small section unfortunately. The rest will have to wait until spring.

[@jultolentino7515]

Useful tip,thank you so much,God bless you sir.

[@valborchardt3596]

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

[@paulam18v]

Great video charie thanks for sharing.

[@CharlieDIYte]

You're welcome Paul. Thanks for the comment.

[@RS-Amsterdam]

Job well done ! 👍👊

[@gordi40]

Once again Charlie great 👏👍🏻

[@ratchriat1716]

love the product great result is is suitable for wood eswell .

[@bmbpdk]

Very well done Charlie!

[@CharlieDIYte]

Thanks mate!

[@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 .

[@scottbeilby2182]

nice work!

[@CharlieDIYte]

Thanks Scott 👍🏻

[@kerryfoster1]

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

[@CharlieDIYte]

Thanks Kerry 👍

[@AHMADKAMALZUBER]

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

[@CharlieDIYte]

You're welcome. If it's a large hole you can get mesh to cover it with first to span the gap.

[@normanboyes4983]

Nice one Charlie👍

[@CharlieDIYte]

Thanks Norman and good to hear from you again!

[@earthenergyhex]

that gutter turned out great, nice work

[@CharlieDIYte]

Thanks Tony. I've got a whole load more to refurbish this summer.

[@branimirnakuoti]

Bravo!

[@oiudsaf]

Really good i like it

[@CharlieDIYte]

Thanks 👍🏻

[@keepitrealoutdoors7549]

Just put a hooe in my barn door. You saved me an ass whooping from a pissed off dad Charlie.😂 thanks man you earned my sub 100 percent

[@CharlieDIYte]

Glad to hear it. Good work and thanks for the sub 👍🏻😉

[@Chris-pv2ht]

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

[@CharlieDIYte]

Thanks Chris. I also had leaks between joints, and I found these kits to be brilliant bit.ly/2OWN6Fz but you have to be careful knocking out the old nuts and bolts as the cast iron is quite brittle and can crack. The B&D files are brilliant aren't they. I had one as a kid and it was my favourite tool by far. Bought this one to replace the old one and I still use it a fair bit.

[@mrv5801]

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

[@Kayyyman]

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

[@CharlieDIYte]

That's a good point - I'll remember that - thanks!!

[@theocole91]

good job i learned this while sitting in the U.S

[@CharlieDIYte]

Thanks Theo!

[@theocole91]

@@CharlieDIYte No! Thank you! Keep it up! I appreciate your simplistic yet detailed approach.

[@amyyates7761]

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.

[@CharlieDIYte]

Hi Amy, yes, this stuff will sort it out. If it's a really large hole you should span it with some Isopon aluminium mesh like this bit.ly/2CEOJmh first. Good luck with the repair!

[@liamfinch4129]

Some masking tape behind the hole would have helped! love your videos

[@CharlieDIYte]

Thanks Liam. 👍

[@lixxydon]

Cheers buddy

[@CharlieDIYte]

Your welcome mate 👊

[@MarcGray1990]

Really good video Charlie! What colour is your guttering... the the rust primer on the inside I love the colour combination haha! Love old cast gutters so much character compared to the new stuff and cast iron guttering is a small fortune nowadays, so don’t blame you for carrying out the repairs! Cheers mate! Marc.

[@CharlieDIYte]

Thanks Marc. I agree. The guttering colour is Farrow and Ball Downpipe, but obviously mixed by Johnstone's. I couldn't get their standard exterior metal paint mixed to this colour so ended up using the gloss paint you see in the video.

[@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

[@CharlieDIYte]

I hear what you say. It's mostly a cost thing of replacing it all and renewing all the brackets. But also they do add quite a bit of character.

[@sixsentsoldiers]

Love old metal gutters.

[@CharlieDIYte]

Me too! Couldn't bring myself to get rid of them. I've got a load to de-rust and paint this summer.

[@scottmclean6301]

Charlie good video. U turn your hand to anything. My question is do you know of anything that I can use to hold metal parts together as I am making some scrap metal art but I don't weld, any epoxy you know of? I think there is a 2 part putty you can get. Thanks.

[@CharlieDIYte]

Hi Scott - thanks! Well, that's a good question! In the next, or possibly third video I'll be showing how I glued a piece of gutter back using JB Weld epoxy adhesive, but the problem with that stuff is it takes 4-6 hours to set, and 15-24 to cure, so you have to hold both pieces together with something whilst they cure. So I saw this stuff in my builders merchants recently www.ebay.co.uk/i/253122443457?chn=ps. Got to say, it looks pretty impressive, and can be put under stress after 7-10 minutes. So that would be my recommendation!

[@scottmclean6301]

@@CharlieDIYte thanks I will look into it. Appreciate it

[@gordonLP]

Hi Charlie, was there any reason why you didn't use a product such as Jenolite after cleaning and before the filling/painting, to add a further layer of rust prevention?

[@CharlieDIYte]

That's an interesting one. I bought some Owatrol Oil from Johnstone's Decorators Centre www.owatroldirect.co.uk/product/owatrol-oil/ for exactly that reason. It looked really good but it says not to use it with paints that contain hot solvents ie xylene - which unfortunately the Bonda Rust Primer does. I was determined to use the Bonda, having exhaustively researched the best rust printer to use and found that the Bonda with its high zinc content looked the best. So the Owatrol is still unopened in the garage! A real shame because the gutters definitely had some residual rust that could have done with being neutralised. I wonder if the Jenolite world be compatible with the Bonda??

[@Sterayb]

Use foil tape to block hole and take it off when it's dry

[@CharlieDIYte]

Good thinking 👍

[@stuartnewman6968]

Just a quick question I am doing a little body work on my car. Is it essential that I use the p.38 if I am going to use a primer ? Many thanks

[@CharlieDIYte]

I'm no expert on car body repairs but no I don't think it is, so long as you're happy with the finish you've got.

[@_tmmy_]

Hi Charlie I don’t know if anyone has asked this because I am relatively new to the channel but would this be suitable for repairing tiny pinholes in a wheelbarrow so I can use it to mix mortar? Like we are not talking of big splits or anything like that but just need the wheelbarrow to not leak when mixing mortar up.

[@CharlieDIYte]

I'd be inclined to give Milliput a go instead. It might be a bit more durable kzbin.info/www/bejne/bHzSaKVtpduYeLM You could even dent the pin hole to give the filler a bit more purchase and then just smudge the filler into the dent.

[@idrandomvideos8138]

I'm gonna try this on a lawnmower deck that has some holes in it

[@CharlieDIYte]

Yes I used it to repair a hole in the plastic vent that funnels the grass out on my Alko lawn mower, damaged when my son mowed over it!

[@sjgear1146]

Will a wall putty work on metal?

[@apache16789]

The finished guttering looks grey in colour but in the video you used Brilliant White Flexible Gloss. So what happened there? Also, did you put the Gloss straight on top of the primer without an undercoat? And one more, why didn't you use Hammerite instead of Johnston's Stormshield Gloss? Do you not rate Hammerite as good as Stormshield or was it a cost decision?

[@CharlieDIYte]

Get you and your eagle eye! Yep you're right. I was going to put an image of the actual tin on, but it's covered in paint so I thought I'd post an image of a fresh new one from t'internet - which clearly is a different colour. Mine is mixed to Farrow and Ball downpipe. I wanted to use Johnstone's bespoke metal paint, but they can't mix that to the right colour so I had to make do with their Stormshield version.

[@dude1052]

can i use this compound to fix steel pipe leak that carried high pressure water supply?

[@CharlieDIYte]

Not sure. Depends how large the hole is, but for high pressure you'd probably be better with Milliput than this.

[@johnfithian-franks8276]

That brought some memories back, my mate and I did a lot of body work on an old mini car, it was so rusty that in the end we had to run ground wires to all the lights because their wasn't enough metal left to carry the 12 votes. fond memories of a misspent youth

[@CharlieDIYte]

Ah, great memories! I used to do a bit of work on cars too, and often there was more rust than metal! Great thing about the Isopon is it still smells as good as it used to!

[@skulls2802]

Gret video, and just like me id repair that too. I am dissapointed you didnt grind, paste and sand on the wifes best carpet like you normaly do XD. Might be a good tip to tell people to use safety specs when ginding too. I know to my cost and have a pernimently damaged eye because i was alazy git and didnt use glasses. Any tips for resoring plaggy windows ?

[@CharlieDIYte]

Cheers mate. Ha! You're right, that would be my usual style. This one was mostly done on the kitchen table, which is looking a bit knackered as a result!! 😂 Thanks for the point about the safety specs. I'll add that to the description. How did that happen? Did you have the guard off?

[@skulls2802]

@@CharlieDIYte Yep, i had the grinder in a vice cleaning some rusty brackets and a small bit of the metel flew off and hit me in the left eye in the Sclera. it bedded its self deep inside and i had to have surgey and still do as it damages the vessles and the Vein. i have to have a injection every 4 - 6 weeks to surpress the beeding. Its called retnal Vein occlusion. You can get cool Bolle glasses, and i use them all the time for everything even painting. love the videos you explain everything perfectly and your work is very impressive.

[@lotuselansteve]

Using the P38 is pretty pointless as it won't add any strength. Simply use another layer of P40, which will add some stength.

[@jasondsouza2209]

The EPOXY MAN!

[@stephencordell6661]

Should have used a wire brush on the grinder much gentler and would have given a cleaner finish

[@CharlieDIYte]

Thanks Stephen. I've been using a wire brush on the gutters (attached to the drill) but I find it just chases the rust/ paint around, whereas the grinder is a much more effective way of exposing the bare metal. I guess putting one on the grinder is more effective?

[@slybunda]

ditch the iron gutter and use plastic.

[@CharlieDIYte]

Nooo - it's part of the character of the house!!

[@deanj6969]

How thin is the metal.....😉

[@boyracer3477]

I'm thinking that a piece of metal tape on the opposite side of the repair would make it very easy to slop on a layer of the filler. Once dried, sand the filler, remove the tape and VOILA !! To be extra anal one could then slather another layer on the side where the tape has been removed, dry and sand it smooth and you would have a perfectly shaped repair.

[@TheMickeymental]

Thanks a lo t, but your French, German, Kiwi, Australian accent really through me off. Kind of gave me a bloody cheek which bled into my Wellington Boots. If the newspaper was page 3 girls your views would go way up in both men and women.

[@concretenmyveins8403]

Next time use a wire brush on your drill

[@CharlieDIYte]

Pretty sure I did. Thanks though 🤔

[@concretenmyveins8403]

@@CharlieDIYte lol ok I thought you were using a grinding disk… also thought you only removed the rust in the repair area before applying the rust paint… video is good don’t get me wrong, I feel it just needed a little more prep. The fix looks good … for now… update in 1 year so we can see , thanks

[@errolkim1334]

2:29 "Mays team plot snap election to save Brexit". Bye Teresa.

[@CharlieDIYte]

😂

[@stakkerhmnd]

I'm the first to comment ! You are not ! Ha! Ha!