We have a leak somewhere. The light lens had a hairline fracture, so I messed around with it and, unfortunately, broke it. Foam behind lens seems fine, so I don't think the leak is there but the lady at the spa store said that might be it anyway. I tilted the tub up vertically, took off side panels and pulled out a bit of foam from both side and bottom from right rear of tub - that seems to be the wettest area.

I am at hard foam around fittings, pipes, and shell. I am thinking I want to remove some of the hard foam to take a look at connections on the bottom. Is this a good idea? If so, how best to remove the very hard foam encasing the shell itself and tubes? Can I just crack that stuff off?

I have a new light lens but instead of installing with Devlon right away, can I just put it in with a silicon sealer until I find the leak? It seems like I should be able to place the lens with silicon and the water pressure after I fill the tub should keep it secure. True? or am I just nuts?

I would just Devcon the new light lens in, it needs to be done anyway...don't mess around with the silicone.

Next place to look is at some nipples that attatch to the back of the moto-massage compartment. They are a source of problems for that year. If you have already ripped the panels off, the nipples (1 per side) are located at the mid-level of the moto-massage compartment and have 1/8" bleed-lines attatched to them. I would bet you have a 90% chance that the leak is from that nipple.

If you just blindly dig away at the foam from the bottom you will never find it...trust me, I have fixed hundreds of hot spring leaks.