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Hotspring Soverign rebuild

First, thanks for this great forum.
I have done quite a bit of reading, and am ready to tackle my project.
I have had since new a 1994 Hotspring Soverign.
Reading on this forum, I am now aware that as luck would have it, the year I bought mine, they switched from Rovel to Enduron and the area unsupported by foam in the light/seat area is succeptible to cracks.
Sometime in the 7th year the dealer came out to fix a leak under warranty, which I was never satisfied was completely fixed. A year or two later, they came again, and I showed them that it was still leaking before they left (the area could be seen with the equipment door off.) They charged me $300, which I paid, promising to come back, and they have since gone out of business.
I put up with the leak, adding an inch or so of water every 4 or 5 days.
Then a more serious leak developed, and I drained it. Now with winter coming I want to see if I can fix it.

I have read about the tendency to leak at the Motomassage return line, and that could well be my new major leak. But I want to first fix the areas that I can see in the light/seat area.

1)I am attaching a photo that shows what appears to be two different materials the dealer used. One time or the other I remember them mentioning that the "kit" from Watkins was about $80, so I am assuming that one of the times at least they used the Watkins product. I have read here that Devcon can be used. Does either of these look like Devcon? The white material is hard as a rock, but the amber material is flexible and can be peeled off. I'm assuming that any old material that isn't "married" to the Enduron should be removed.)

2)Is it possible to use fiberglass resin and mat to reinforce the entire area
under the seat/light? This would hopefully prevent any new cracks from developing. Please note that I am not concerned about appearances. As long as I can make it hold water, I will be happy.

3)Besides the cracks around the light, unbeknownst to me, it had been leaking all around the light, and I have read that there are retrofit units available. I never used the light anyway, and was wondering if this could be closed off possibly with fibergalss?

TIA for any and all help.

Posted by on 2007-09-20 12:47:00. (10936)

Wow, a dealer did that?

The "Kit" is about 200, is consists mainly fiberglass and Permalite (Another 2 part epoxy)

It appears the dealer smeared some DEVCON on there, I'm unsure what the brown stuff is, might be a heavy density foam, but honestly, not sure.

300 for a hatchet job is a bummer.

To properly repair the crack, you really need to support the entire wall on the equip compartment side, which is why they'll send plenty of permalight and fiberglass in the repair kit.

Posted by on 2007-09-20 15:34:27. SW Florida (10937)

Thanks swine.
After further investigation, I see that they did a more substantial repair on the other side. I can see some mat material (maybe 2" x 2" in it. Does this look more like a professional job should?

BTW-I should have stated that I had recently replaced both pumps and the heating element, so I would like to try to salvage this thing.

Posted by on 2007-09-21 17:00:40. (10947)
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