Making a Hot Tub Shell

First the acrylic sheet is placed into the heater with the mould in place

The heated acrylic sheet sags as it is lowered into position

A vacuum former sucks the soft acrylic sheet into the mould

The shaping of the acrylic sheet is completed

The back of the acrylic sheet is sanded for grip

Bonding is applied

A mixture of polyester resin & chopped fibreglass is sprayed on

The fibreglass resin is cured in an oven

Closed cell foam insulation is applied to rear of the acrylic shell

The edge of the shell is trimmed to shape

Holes are drilled in the acrylic for the jets and fittings

The finished shell is finally ready for further assembly!