Repair and Refinishing a Hot Tub

Spa Pack,Pump and light assembly

chriscormier — Sat, 03 Sep 2011 15:00:13 +0000

The spa pack and pump arrived and the quality of both look to be quite good. The pack has several leads that connect directly to the pump, blower (I am going to use the original blower that came with the hot tub) light and ozone. I will get an ozone generator in the spring once I know that this project is a success. This purchase was the most expensive part of the project. The cost took a bit to absorb into the budget.

Installing the spa pack and pump was pretty straight forward. All the PVC was 1 1/2″. I used flex PVC where I could to reduce the number of 90deg angles and to allow for any expansion or contraction that may occur with the temperature changes over the year. On the threaded connections I used Teflon tape. The ozone injector will be installed later in the small clear line at the top of the picture below.

After a day of allowing the connections to dry, I began to fill the tub to check for any leaks in the tub itself or any of my plumbing connections. I had one leak on one of my PVC glued connections, but it was easily sealed. The threaded connections were all sealed except for the diverter assembly on top of the pump. A quarter turn more on the collar fixed the leak.

Total expense to date: $1,797.07

Hot tub parts, pump and spa control system

chriscormier — Mon, 11 Jul 2011 15:26:52 +0000

I neglected to include some pictures of other parts to the project that had arrived a while ago, so I have included them in this post. No new construction pictures to show. The spa control system and pump are ordered, so once they arrive I can finish up the plumbing and hopefully get a running hot tub soon.

Filter housing

Air induction splitter

Water splitter

Misc plumbing parts

Ozone injection Venturi

Dual stream jets

Single stream jets

Cabinet vents

Misc electrical parts

Spa GFCI Disconnect

Total expense to date: $1,152.10

More progress made….

chriscormier — Sun, 19 Jun 2011 15:15:09 +0000

I added the composite deck board between the walls and the hot tub. I also added in a water diverter since the boards are flat and not angled. Any water that gets under the lip of the hot tub will not go inside. It is a piece of “J” channel that is attached by liquid nails.

I installed the 4 jets into the tub as well, the rest of the plumbing will need to wait for the control pack and pump.

The side walls are attached until I can get the rest of the parts needed. I did not want the rain to keep getting inside the wall area. I will be purchasing the pump and control pack next. The plumbing and electrical can be completed once I have them in place.

Total expense to date: $791.76

Hot tub walls and walkway supports

chriscormier — Sat, 07 May 2011 18:50:04 +0000

The wall supports for the hot tub are complete. 2x6PT walls were used so that we can insulate the walls to minimize any heat loss. We assembled 3 sides first, then slid the hot tub into place. The hot tub is resting on 2×4′s so that we can easily pivot the tub into place once the composite boards are installed. I placed an order for the jets, filter and other plumbing pieces, so they should be arriving soon.

Total expense to date: $495.56

Framework for the hot tub and deck access

chriscormier — Fri, 06 May 2011 01:31:18 +0000

We decided to locate the hot tub in between the pool deck and the deck that is attached to our house. In order to create a safe access way we need to build a walkway from the old deck to the new deck. Once the project is complete we can remove a section of railing at the pool deck and we will have access to both the hot tub and the pool from the house. It was a bit more than originally planned, but we think it will be the best overall option for the hot tub.

The small ledge off the current pool deck was constructed first and then the hot tub support floor was constructed so we could determine how close to set up the walkway. Adding in the walkway unfortunately created an additional expense and a trip to Lowe’s for more PT and additional support blocks.

Total expense to date: $495.56

Winter has ended…

chriscormier — Wed, 20 Apr 2011 14:45:31 +0000

Well the cold snowy winter has finally left us and it is time to continue with the project….

I picked up the lumber and blocks that will be used to support the hot tub. I also need to make a short ledge off of the current pool deck so that people can access the hot tub safely. Here are some pictures of the location for the hot tub and the materials I picked up. I will be working on this part of the project before I finish up the jets and plumbing in the tub.

Total expense to date: $363.49

Final epoxy coating applied

chriscormier — Sun, 05 Dec 2010 16:09:03 +0000

The final coating was applied last week and it has finally cured. My recomendation to anyone using this epoxy coating is to divide it into at least 4 coats. You can probably even get 8 coats out of the epoxy kit. The only difficulty would be dividing up the colorant in equal amounts since there is so little to mix in the first place. Overall I am pleased with the results. Next step is to start attaching the fittings and pick out the jets.

Total expense to date: $195.42

Epoxy coating #2 applied

chriscormier — Thu, 25 Nov 2010 00:20:11 +0000

Here is a picture of the second coat of epoxy, all the tiny cracks are sealed after applying the second coat. There are a few spots that the epoxy will not adhere to. The silicone remnants must still be on the surface for some reason. I used acetone, rubbing alcohol, muratic acid, and sandpaper to try to get it all off, but it is being stubborn.

Epoxy Coating #2

Total expense to date: $195.42

Repairs are finished!

chriscormier — Mon, 22 Nov 2010 23:15:41 +0000

The repairs to the tub are finished and the epoxy coating is being applied. The tub was sanded with 100grit sandpaper and cleaned with sulfuric acid before applying the epoxy coating.

We decided to go with a dark blue color for the tub. Applying the epoxy to the tub surface is a bit tricky. Thin coats are needed, if you apply too much it can drip easily. With the cold temperatures in the Northeast, it is going to take several days for each coat to cure. The instructions show to mix up half of the containers, but I found out that that amount is too much to mix at one time. I will be able to get 3 coats out of the material that I have. Hopefully by the 3rd coat the drips will not show too much. The dark blue color looks nice and it if a high gloss finish.

First coat of epoxy

Total expense to date: $195.42

Parts ordered….

chriscormier — Sat, 20 Nov 2010 20:20:25 +0000

We needed to purchase a few parts to make sure that the tub had all the correct sized holes, A skimmer, return drain, and an air valve. We also purchased the epoxy coating, a few brushes, roller and mixing bucket for the epoxy that will cover the old surface. Here are some pictures of the items:

Water Suction Fitting, The original one is on the right.

Total expense to date: $195.42