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.

hi, i'm new to this site and stumbled on this by searching for leaking lens prob with my ~95 hot springs sovereign 110v model.

i'm wondering if i could also get that info on the lens/epoxy and any other additional tips.

thanks in advance,
steffes (dayton, ohio)

Regarding buying the 2-piece lens, you need to find a Hot Springs dealer in your area.
If you can't, you can try to contact Olympic Hot Tubs in Seattle, WA - ( http://www.olympichottub.com )
Phone (outside Western WA): (206) 286-0700.
I found the "special" epoxy glue online, and ordered it. (Manufacturer = Devcon, Product Name = Plastic Welder - Details are below).
The GlueDepot.com requires a minimum 2 CASE !! purchase to get the mixing-nozzle dispenser, which fits into a regular caulk gun. When I contacted Olympic Hot Tubs to buy the light, they were out of the "Plastic Welder", but they referred me to their glue supplier in Seattle. I bought plenty of the glue from them, and got the dispenser and some extra mixing nozzles for a few dollars more.
You can probably find it locally as well, with some detective work. Try finding a local Hot Springs Spa authorized dealer for advice.
(Note: they sell service by the hour, so they won't talk you through doing the job yourself, but if you buy the lens replacement from them, they'll probably help you find the Plastic-Welder glue.
I got the plastic welder shipped from TheGlueDepot, but it arrived after I had finished the job. (Now I'm ready for anything plastic to break!)
NOTE: The lens kit is actually 2 pieces - the actual lens piece threads into the base piece. Be sure they are tightly threaded together before you glue them to your tub: you don't want to have to try to tighten them up later, working against your new glue-seal...
It sound like you already have your old one out: my tub has the "bumpy" textured surface, so the lens actually sits in a slightly recessed circle. (See my pictures in the topic on this forum.) That meant I couldn't just use a chisel as suggested to remove the old lens. The lens replacement kit from Olympic Hot Tubs came with an instruction sheet that covers that, and it meant I got to buy myself a new Dremel tool and cutting discs. That also helped a lot with cleaning the old epoxy off & resurfacing the backside.
I saved my photos & notes as a Word document, and emailed it to myself for just this occasion.
I tried to email it to you through this forum, but it won't go through. If you want me to send it to you, send your email address to me at my email: zafereo@yahoo.com.

PS - MY SINCERE THANKS GOES OUT TO Dan.the.spa.man FOR GUIDING ME THROUGH MY LENS ADVENTURE !!!
My tub was back up quickly, and my shore leave was awesome because of it. Now we're back diving Alvin in the North Pacific, and I'd give my left arm to be able to soak in the tub every morning. ( The water temp here is 49, and my 7mm wetsuit only does so much !)


Merchant : THEGLUEDEPOT.COM
Date/Time : 09-Mar-2008 10:51:15 AM
Transaction ID : 1759131968

========= ORDER INFORMATION =========
Invoice Number : 1990
Description : PLASTIC WELDER in the 50 ml auto mix dispenser. One Of the
Most Versatile And Strongest Plastic Adhesives Made. Requires application
gun and mixing nozzles for auto mix. Free Gun With Two Case Purchase.
Total : 28.65 (USD) (2 tubes of the Plastic-Welder epoxy glue).

Can't thank you enough for info included in post. I've been struggling with the lense leak and trying to figure out what that hard white stuff that wouldn't come off was. My HotSprings dealer where I bought the spa "reconditioned" (Sovergn 93)told me to go to the hardware store and get silicone- tried it but it did not hold. I'm going to try to find less than 2 cases of the Devcon product next. Wan't to soak my aching body after climbing around on the ground trying to fix my tub grandma!

May I add 1 thing - when cleaning the old glue off I would recommend drilling through the old plastic stud holes so the new glue will seep through the holes. Don't push real hard when drilling.

Thanks

Pete