Issue 48 AUG 25 web - Flipbook - Page 70
Restoration and Reproduction
of Ornamental Lead Gutters –
Wakehurst House
In early 2024, we were approached to assess a collection of highly ornate lead gutters that had been removed
from Wakehurst House and placed within the chapel for safekeeping. Upon arrival, we identified 74 sections
of original lead guttering, each unlike anything we had encountered in our many years of specialist leadwork.
Following our investigation, we believe these ornamental gutters date back to the 1930s. Each length weighed
approximately 88 kilograms and exhibited varying degrees of damage and deformation, likely caused by decades
of strain on the original supporting fixtures and the inherent weight of the lead itself.
Restoration of Original Gutters
To begin restoration, we transported a sample section
previously removed from the barn-to our workshop. Using
localised heat application, two hydraulic presses, a custom-made jig, and traditional hand tools, we successfully
reformed the section back to its intended profile. This
method was then replicated for the remaining 74 sections.
The full restoration process included:
• Cleaning and surface preparation.
• Structural lead weld repairs.
• Installation of new 50mm Code 8 lead overflow pipes,
welded to the reverse of each finial.
The work was completed in stages across five collections
and deliveries, involving an estimated 6–8 tons of lead
guttering.
Formation of New Ornamental Gutters
This project marked a major development in the
ornamental division of Lead It Be. While we had previously fabricated bespoke lead pipes and hoppers since our
founding in 2015, these gutters represented an entirely
new challenge in terms of scale and complexity.
3D Scanning and CAD Development
To begin, we partnered with Adrian from Buzz
Productions to carry out 3D scanning of a representative
gutter section. Within days, we received CAD files displaying the profile and damage of the existing gutters.
Adrian then cleaned the scans and developed accurate
digital models for the gutter face, acroterion, lead finials,
and internal brass brackets.
Mold Creation and Sand Casting
Given the requirement for just 12 linear metres of new
guttering, we commissioned 3D CNC to produce a precision mold using modelling board. The mold, machined
on a table router over 13 hours, was used for sand casting
with Petrobond. After applying parting powder and sieving sand onto the mold within a timber former, we produced high-fidelity impressions to pour molten lead into.
This process was repeated for each section required.
Finial Casting Challenges
Initial attempts to replicate the intricate finial details via
lost-wax casting proved problematic, as we struggled to
maintain the sharpness of the decorative features. After
multiple refinements, we opted to create an aluminium
casting block, manufactured by Saxton Engineering in
