I've read several posts mentioning leaks around the light-lens on Hot Springs spas. My Sovereign has this issue, and I was wondering if anyone here has successfully removed & replaced one of these lenses before. I was able to remove the top two nuts from the plastic studs, but the 3rd (bottom) was rusted, and just disintegrated, also taking with it the remains of the bottom plastic stud. (It appears as if someone might have tried over-tightening this one nut in the past to stop a leak.) (Pictures Attached)
So, I have the 3 nuts removed, but there is this hard, white substance that looks like it was painted over the sealing area and the nuts when this lens was installed. The lens won't easily push out (into the tub), and I'm wondering if I should try cutting away this "paint" or "sealant" from the rim of the lens. Maybe then the lens would push out... ???
Anyone have any advice or GRAVE WARNINGS ??
I'd love to be able to use this tub while I'm in Seattle on Shore Leave !!
Thanks, Anton

Just use a chisel and a hammer from the inside of the tub and gently tap around the edges. It should pop right out pretty easily. Then use a 3"disk grinder to remove the old adhesive from the shell.

Do you have the new lens? There is a different style that retro-fits in with some devcon adhesive.

I don't have the replacement lens yet - Our local supplier is closed weekends. I have a service call scheduled with them in about 10 days to look at it, but I'd much prefer to find out I could do it myself with the right parts & prep (& knowledge!).
I'll make sure I find the proper replacement for the lens before I try anything. Do you know of any alternative sources (online, etc.) for the lens? (You mentioned a different style that retro-fits in with some devcon adhesive.) Is Devcon Adhesive what I see painted on the back of the shell, and should the new lens be installed using it Devcon?
Should the Devcon be siliconeRTV? (I assume epoxies would be bad, and I wonder if that's what I see
I've looked at Spapartsnet.com and other sites, but haven't stumbled on anything like the lens I need.
So, the lip of the lens on the inside (water-side) of the tub is strong enough to pop the whole thing out with a carefully placed chisel?
I guess I can try wrapping a chisel in a t-shirt to prevent scratching the sealing surface.. (Picture below..)
Home, and the hot tub are actually in Seattle.
Looks like you're in Connecticut. I work for Woods Hole Oceanographic as a Tech & Pilot-Trainee on the deep submersible, Alvin. You'd think I could figure out how to fix a leak...
THANKS FOR YOUR HELP!

Wrapping it in a rag would be fine, but I've done about 150 replacements or more without any problems. With those white shell tubs you just have to be careful not to pry between the lens and the shell too much...let the chisel and hammer do the work with quick short blows. Start at the areas where those screws are (from the inside of the tub though) in your pics. Sometimes the whole thing pops right off with only a few shots.

With the tub already drained and all the parts and tools together, it should only take about 15 minutes to do.

The new lens is 2 pieces and a much thicker plastic. The Devcon is a two part epoxy that I get pre-packaged by HotSpring.

Sounds like some cool work you do...I went to URI for Wildlife Biology and Marine Affairs, so I'm somewhat familiar with that program.

I'll send you a private message with some info for the lens/epoxy.