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Polynesian Spa rebuild

This is simply a polynesian spa (circa 1987) that desperatly needed a new cabinet. The original was made of redwood, but was in such poor shape and had many, many layers of paint on them. I tried to resurface them, but the damage was to extensive.

I rebuilt the entire cabinet out of western red cedar framing and trim, used reclaimed tongue and grove white cedar slats, and the understructure is all pressure treated wood. Every joint is mitered and dado'd, glued with all weather carpenter's glue. Absolutely no nails or screws are visible. The access panel is designed to be completely invisible. The only clue it exists is a small knob that is used to pull the door open.

Equipment modifactions include:

Replacement of all 5 main jets
Replacement of 2 thearapy jets
Resealing of 2 thearpy jets
Retrofiting a new jet selector valve
Adding an underwater spa light
Replacing the wet end
Replumbing to relieve stress on the pipes and make room for the new valve.

Beileve it or not, I did this all with a cast on my leg, completely immobilized! Now talk about a challenge!

Many people have asked for details on how to build a cabinet, and unfortunately, due to my physical dissability at the time, I was only concerned with finishing the project, and did not detail the build. I have 2 more to do currently, and hopfully they will be detailed. They won't be started until next spring/summer, however.

Posted by on 2005-11-28 03:33:12. Albert Lea, MN (5339)
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