Replacing the Spa Light Body

Step 1:

Using the wire saw, cut off the front flange of the light body at the spa wall. Do not let the blade touch the shell as it can easily burn a hole in it.

Step 2:

Holding the light cord, pull the rest of the assembly out of the light tunnel from the equipment side of the spa

Step 3:

Straighten a coat hanger and use the bent end to remove any remaining parts from the tunnel.

Step 4:

Remove the nut from the light body, and keep the nut nearby.

Step 5:

Use your fingers and/or a flat screwdriver to remove as much old silicone as possible from the front of the shell hole. Be careful not to tear or puncture the shell. On the back side, peel as much of the old silicone away from the shell.

Step 6:

Apply a generous amount of clear silicone on the back side of the shell using your index finger.

Step 7:

Using your coat hanger, run it from the water side of the spa through the light tunnel, and hook the nut onto the bent end. Pull it back through the light tunnel and grab the nut with your fingers.

Step 8:

Carefully lay the flattest part of the nut onto your ring of clear silicone and let it cure for about 1 hour, (but immediately remove all excess silicone from the threads of the nut).

Step 9:

Remove the light lens from the new body.

Step 10:

Put a new gasket onto the back of the lens.

Step 11:

From the water side of the shell, put the lens body through the hole and slowly screw it in until the nut on the back starts moving or until the gasket makes contact with the shell.

Step 12:

Be careful when performing these steps. While holding the outer ring of the light body, insert your bent copper tool. Spread the ends and catch the nut as pictured above. (Avoid damaging the threads). Use the tool to screw the nut, (counter-clockwise), snugly into the silicone. Over tightening can distort the gasket and cause a leak.

Step 13:

Carefully remove the copper tool.

Step 14:

Remove the light bulb from the light reflector. Using your bent hanger again, run the hooked end through the light tunnel and hook the light reflector. Pull it as close as you can to the light body.

Step 15:

Using needle nose pliers, grab the black light bulb receptacle, pull the assembly against the light body and thread it on. Be careful not to damage the black light bulb receptacle.

Step 16:

Insert the light bulb.

Step 17:

Put a little dish soap on the O-Ring to act as a lubricant so it does not stretch during the next step.

Step 18:

Replace the O-Ring in the light housing.

Step 19:

Replace the lens.