Virtual Factory Tour
Many of you have asked us how our spas are made. We are happy to provide you with this new feature to our web site. In this
section, we will show you how we take a large, flat piece of Acrylic and
turn it into a beautiful Discount Spas Direct Hot Tub.
Sit back, relax, and enjoy your tour of the factory!
STATION # 1 -
VACUUM FORMING
 |
To make the shell of the spa (the inside of the spa), we put a sheet of the Acrylic into the Hydraulic Clamping Frame and place it in the Vacuum Forming Machine. We heat the sheet to 395° Fahrenheit until it is semi-molten and soft like stiff putty or clay. The molten sheet is then stretched over a vacuum mold that is the same shape as the spas' shell. As the acrylic sheet sags into the form we apply a vacuum to the underside of the sheet and it sucks it into the form which shapes the spa. |
|
 |
|
After it cools, it is removed and
prepped to accept the spa structure. At this point it is very
weak and flexable. |
 |
STATION # 2 - FIBERGLASS & FRAMING
At this station, we put the Acrylic Skin
Finish onto a holding fixture to protect it's shape and make it stronger.
 |
We put many laminates of resin and
fiberglass to achieve an overall thickness of 50 - 100% more than
the industry average. The first laminate is the most critical. It will bond the two surfaces together to make them one. It is a specialty resin called vinyl ester which bonds the two together both chemically and mechanically. It will also act as a corrosion and vapor barrier to guard against delamination and blistering. |
|
Additional Layers of resin and fiberglass are then applied to provide greater strength and thickness to the shell. |
 |
| We then brush down this first set of layers with special brushes to even out any areas that may be not covered enough...or that are too thick. This is in preparation to a final layer of resin and fiberglass. |
 |
 |
By fiberglassing the frame to the
spa shell we unitize the wood frame and spa shell to make the
full support package of the above ground spa. Many spa manufacturers
no longer support their spas with a frame. They simply set the spa
shell in the wood cabinet and fill it full of foam. Doing this
eliminates the frame and also foams over 200 - 300 plumbing parts
and connections. We build a sturdy frame around the shell to provide this stability and strength. (see further steps) |
|
Urethane foam is the best
insulation material available to date; but it is a weak structural
material and costs much less than the fiberglass, resin and
construction that we use for our structure. |
 |
STATION # 3 - DRILLING
& INSULATION
 |
At our next station we
trim off the edge of the spa and drill in the holes for the water & air jets, suctions, skimmers, controls, etc. |
Note: There
are many misconceptions as to what insulation does and what it will do
for you in the portable spas application. We put one inch of
insulation on the spa shell. That is the equivalent to 4 inches of
fiberglass insulation or 2½ inches of high density polystyrene which
is what all spa covers are made out of. This along with the
enclosure is plenty of insulation for even the coldest environments. We can also do full foam for areas that have colder climates, however this is done after the hot tub is fully tested, filled for 24 hours and certified defect free. |
 |
STATION #4 -
PLUMBING, EQUIPMENT & WATER TEST
At our next station we install all of the
plumbing & equipment to carry the water and air for therapy & relaxation.
 |
Both water jet and air jet therapy
are available on our spas; many manufacturers do not offer both
types. Air jets agitate the water all around you providing general
non-specific therapy & relaxation. |
|
Water jets point to a specific area
of the body and thus provide specific relaxation and therapy. Our
water jets are individually adjustable for flow and intensity,
giving each user a wide variety of therapy features. |
 |
All the tubes that carry the water from the pumps to the jets are then connected. |
|
 |
Every spa is completely water and
function tested before it leaves, the factory. Many manufacturers
only test 1 out of 10 or 20. You can see by the photo how ridiculous
it would be to fully foam the underside of your spa and thus cover
up this plumbing. The dead air space provides heat retention and the
components generate heat up to 100 plus degrees. The only reason to
full foam fill under a spa is for support instead of using a frame.
|
|
We have had our equipment
manufactured by the same specialist for thirteen years per our
specifications. Consistency and quality is the benchmark of
excellence. |
 |
-
We use Waterway and Hayward Pumps -
they have been supplying water pumps and water support devices for the
pool industry longer than most, and the spa industry for the last 25
years.
-
Note that with all of the plumbing
pipes and fittings that it would be very difficult to locate and
repair a leak had the cabinet area been foam filled.
-
Because we manufacture and sell
direct, we can custom place jets for your therapy or relaxation needs.
STATION # 4 -
WOOD CABINET & STAINING
 |
At this station we attach
the exterior siding to the spa frame. The structural integrity of the
portable spa is not dependent on the cabinet as it is with many spa
manufacturers.
|
 A very high quality of clear heart
redwood is used for the siding. This is the best exterior natural
wood available. Many others use red wood, i.e. western red cedar,
stained fir or pine. We have been with this lumber mill for 15 years
to insure a supply of this special wood material. As you may be aware,
old growth redwoods are no longer allowed to be cut. The redwood that
we use is from the very inside of the second and third generation tree
growth. The branches were small then so, if there are any knots, they
are very small and tight.
|
We have three standard Water Based
Sealer & Stains: redwood, coastal gray wash, and natural.
|
 |
For Spa Covers we have the industry
standard 3-1/2" to 2-1/2" tapered cover with locks on four corners
made of high density bound polystyrene foam and marine grade vinyl. We
have three color options: rust, tan, and gray.
STATION # 5 SPA
DETAIL & SHIPPING
 |
Each spa is detailed and checked
out for final quality assurance. |
Shipping to you is the last step of
our manufacturing process. High Quality Product at a Reasonable Price
plus Customer Service and Satisfaction is our Goal. That makes REAL
VALUE.
|
Now It's on it's way to your home! |
Go Back
|
Dare to Compare - Lowest
Prices Guaranteed!
