Sundance Rotten Base

[Mikey_in_NY]

To my horror I recently became aware the lumber base (kickboard) on my 9 year old Sundance Hawthorne had gone rotten to the point where it was basically falling apart. Called Sundance about this who informed me they could not help with a spa this old, but did advise I should replace it as  long-term it could affect the structural support as well as let vermin in under the tub. Tub has run 24/7 trouble-free for all 9 years through some very cold winters here in Buffalo, and is used on average about 3 times per week. I don't know if Sundance have moved away from using pressure treated lumber, but if not then they certainly should.

Purpose of this post is to inform other owners of my solution (it worked out great for me but do this at your own risk!). Here's what I did...

1. Drain tub, remove cover, cover lift supports/brackets and rear corner surrounds.

2. With the help of my two adult sons pushed rear of tub forward around 3 feet in the concrete pad (3 people was a real struggle, 4 would have been much better).

3. Used a scissor jack to lift front of tub about 10" just to get a better grip underneath. Important - scissor jack placed directly under vertical frame strut.

4. Carefully lift tub onto its back using a LOT of cardboard between concrete pad and back of tub to cushion it. Secured with rope as it had a tendency to fall forward.

5. Used an aerosol spray can to indicate locations of all 4*2 cross members (see photo).

6. Unscrew outer 2*2 rotten kickboards. Cross members are only attached to these, two of them were also going rotten.

7. Visited lumber dealership to purchase replacement pressure-tread lumber, however they had close-out (50% off) sale on composite 4*2 so I went for this. Had to get two 8' lengths cut down center to give me the 4 outer pieces.

8. Drill pilot holes into outer composite 2*2 surrounds and screw to base of tub (over existing plastic sheet). Cut and screw 45 degree corner pieces.

9. Cut cross members to length and screw to 2*2 surrounds using aerosol spray marks for exact locations.

10. Four adults carefully lowered tub back onto concrete pad and back into final location (tip - placed sleeping bags under front end in case weight became too much and we had to drop it last few inches, but in the end not necessary).

Total cost: $110 for composite plus $40 stainless deck screws. About 12 hours total labor.

 

 

[Treysoucie]

On 8/12/2018 at 12:37 PM, Mikey_in_NY said:

To my horror I recently became aware the lumber base (kickboard) on my 9 year old Sundance Hawthorne had gone rotten to the point where it was basically falling apart. Called Sundance about this who informed me they could not help with a spa this old, but did advise I should replace it as  long-term it could affect the structural support as well as let vermin in under the tub. Tub has run 24/7 trouble-free for all 9 years through some very cold winters here in Buffalo, and is used on average about 3 times per week. I don't know if Sundance have moved away from using pressure treated lumber, but if not then they certainly should.

Purpose of this post is to inform other owners of my solution (it worked out great for me but do this at your own risk!). Here's what I did...

1. Drain tub, remove cover, cover lift supports/brackets and rear corner surrounds.

2. With the help of my two adult sons pushed rear of tub forward around 3 feet in the concrete pad (3 people was a real struggle, 4 would have been much better).

3. Used a scissor jack to lift front of tub about 10" just to get a better grip underneath. Important - scissor jack placed directly under vertical frame strut.

4. Carefully lift tub onto its back using a LOT of cardboard between concrete pad and back of tub to cushion it. Secured with rope as it had a tendency to fall forward.

5. Used an aerosol spray can to indicate locations of all 4*2 cross members (see photo).

6. Unscrew outer 2*2 rotten kickboards. Cross members are only attached to these, two of them were also going rotten.

7. Visited lumber dealership to purchase replacement pressure-tread lumber, however they had close-out (50% off) sale on composite 4*2 so I went for this. Had to get two 8' lengths cut down center to give me the 4 outer pieces.

8. Drill pilot holes into outer composite 2*2 surrounds and screw to base of tub (over existing plastic sheet). Cut and screw 45 degree corner pieces.

9. Cut cross members to length and screw to 2*2 surrounds using aerosol spray marks for exact locations.

10. Four adults carefully lowered tub back onto concrete pad and back into final location (tip - placed sleeping bags under front end in case weight became too much and we had to drop it last few inches, but in the end not necessary).

Total cost: $110 for composite plus $40 stainless deck screws. About 12 hours total labor.

 

 

Heck of a job! im about to do something similar to a 2007 Sundance Cameo, but my bottom is plywood. i plan to replace it with PVC 3/4" sheeting

 

[Bill_in_NZ]

Just discovered your post.. Our Sundance is only four years old but on one end (facing the prevailing wind), it is completely rotten underneath. Your step-by-step guide will be very helpful as were the photos, just to see how it is constructed. First step will be to contact the supplier to get assistance to turn it on its side - they have handling gear and a couple of big guys! Looks like I’ll be doing the same rebuild.