Does ANY old house repair ever turn out like you think it will? John at the Devil Queen advised someone the other day,
3) A high threshold for frustration is helpful if not a must. Things
almost never go the way they are supposed to, so be prepared. Beating
your head against a wall is a perfectly acceptable coping mechanism.
4)
The general consensus among Housebloggers is whatever you think your
budget will be (rounding up), double it. This will be the MINIMUM that
your project will cost. To date, our costs have been exactly double of what we budgeted.
While his whole post is all true, I'd like to add that your projects will take AT LEAST twice the time you think they will.
The Yankee gutter project still isn't finished. All my worrying about the topcoat paint the other day was premature because we haven't even gotten to the point that we can paint yet. We have learned alot, though!
The prep was serious work. Roof tar over paint over rust is no fun to strip. We did find another use for the Silent Paint Remover, though - it cooks tar off pretty efficiently.
Austin cooking tar. The fumes really stink.
Then we washed the whole thing down with a product called Marine Clean, which is some kick-ass cleaner. It actually dissolved bits of paint that were left over and removed the tar residue. They claim it doesn't hurt wood, which made me think it would've come in handy when we were cleaning tar off wood floors in the house last winter. I'd test it out for everyone, but we're out of interior tar floors. I hope.
Then the Metal Ready was pretty easy. Just spray down the entire surface with the spray bottles they send with the product, keep it wet for 20 minutes and then rinse. We used a garden hose, which is the ONLY advantage to doing this outside.
We let that all dry overnight and started the next morning with the POR-15. It's alot easier to use than I thought it would be. It goes on nice and smooth and level. The fun started with the fiberglass.
Resto-Motive, the company that markets POR-15 sells a fiberglass called Powermesh that we ordered to use to bridge the rusted out places in the gutter. Clearly, the market for the Powermesh/POR-15 combination is in the old car restoration business, repairing rusted out floorpans and pickup beds. They sell a kit for this and the only real instructions are concerning this kit. After scrounging all over the web and reading old car forums, I cobbled enough information together to figure we could apply the fiberglass.
And we did, really. The unforeseen problem was that we didn't know how much additional POR-15 we would need due to the fiberglass. We had figured, based on the square footage and 2-coat requirement, that we had more than enough.
At first, we had decided to line the entire tray portion of the gutter with fiberglass, but as soon as we started applying the POR-15 to the fiberglass (which was pressed into the initial coat of POR-15) we realized that it was going to take ALOT of POR-15. We decided to cut the fiberglass and apply it ony to the gaps and holes, but even so, we had only enough POR-15 to do a third coat on the fiberglass areas, which wasn't enough to completely seal it.

Then it rained and the gutter leaked through the remaining pinholes. The End.
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