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 Gillingham using their 5-axis CNC machines. This provided a consistent and accurate reproduction of the original finials.
Fabrication of Brass Brackets
The internal brass brackets presented the greatest fabrication challenge. After reaching out to multiple casting specialists—none of whom could accommodate non-ferrous metals—we decided to machine the brackets from solid brass using 5-axis CNC technology. Each of the 40 brackets was individually cut, taking several days of precision machining.
Once received, the bracket ends were fluxed and soldered to enable proper adhesion with lead during casting. Using a graphite casting block, lead was poured around the brackets. We then spent an additional two days meticulously cleaning off heat marks caused by the soldering process.
Assembly and Welding
With Code 8 lead as the base and rear structure, we worked with a local engineering shop to machine the edges for a straight finish. Their metal folder was adjusted to accommodate the thickness of the lead and to prevent material thinning, allowing for precise bending to the required angle.
We then:
Welded the brass brackets to the back of each lead base.
Lifted and positioned the cast lead faces.
Welded the faces in place with six welding passes with a No. 5 tip torch.
Chamfered external weld areas to allow for shaving flush, ensuring a clean, flat finish without compromising the structural integrity.
Formation of New Lead Pipes
As part of our ongoing commitment to high-quality ornamental leadwork, we also undertook the formation of new lead pipes to accompany both the restored and newly fabricated gutters. Although we’ve produced many bespoke lead pipes and hoppers since our establishment, each project presents its own set of design and fabrication challenges that continue to push and refine our craftsmanship.
For this project, precision and visual consistency with the original period features were essential. To achieve this, we collaborated with our local engineering shop to produce a custom aluminium casting mold, designed specifically to replicate the original shell-pattern fixing heads. This mold was co-designed to be bolted and unbolted with ease, allowing for the safe removal of each newly formed lead component without damage or distortion.
We selected Code 8 lead as the base material, ensuring both the structural integrity and longevity required for exterior architectural applications. Each pipe was formed using a guillotine and metal bender, shaped with care to maintain consistent diameter and wall thickness throughout. Where necessary, hand-formed decorative details and period-accurate collars were added to match the historical aesthetic.
All welded joints were completed using precise heat control and traditional lead-burning techniques, ensuring a strong watertight seal and a clean finish. Once fully formed, the pipes were treated and finished to visually harmonise with the patina and character of the existing architectural features at Wakehurst House.
The final result was a seamless integration of new craftsmanship into a historic environment—fully functional, durable, and faithful to the original design intent.
Completion of works
We couldn't be more grateful to our team for their incredible hard work and dedication throughout this project. At the time we received confirmation to proceed, we were already inundated with existing commitments. However, after a team discussion, we unanimously agreed that this was an opportunity we simply couldn't pass up.
With that decision made, we devised a plan to honour our pre-scheduled site work during the day, and dedicate our evenings to the restoration. For five consecutive weeks, our team worked tirelessly in the Lead It Be workshop from 7pm until 11pm—often pushing later into the night. There were several 1am finishes, and even one remarkable 3am session to ensure we met the tight deadlines required for this project.
It was a true team effort, driven by passion, craftsmanship, and pride in our work.
Lead It Be Leadwork Specialists have been set up to provide the client market with high quality specialist services as a response in the demand for the roofing and conservation of buildings. Lead It Be is developed of a small family run business and will soon set up to be a well-known roofing contractor based in London. As experienced roofing contractors, we are committed to the professional development of our staff, ensuring we are fully compliant with the construction skills certifications.