Fixing my above ground pool with cnc plasma

[TJS]

Ok. A little picture heavy. Many above ground pools rust because many hack installers are subed from the pool company. They put dirt up against the walls of the pool. The dirt holds the moisture and rots the lower track and the walls. Also the liner normally holds moisture which also compromises the cheap metal walls with minimal corrosion protection. Yes the pool is around 12 years old but a new pool is not in the budget right now. This pool was 6500 12 years ago installed. Same pool on 2024 is 13k plus 1000 removal of old one and pool company says a permit needs to be pulled which they are wrong. Anyway I decided I can fix this pool and make steel patches as well as a new stainless skimmer basket plate. I have had a few trials and tribulations as I have never done this before. There are some vids on fixing walls but I went my own route. So far with a new liner and other items I have 800.00 into this project. I used PL marine as well as flashing tape to secure the patches to the walls. The tape is to protect the edges of the sheet metal I used so it does not cut into the new liner.

Take note of this hole I cut out. This later on gives me problems.

This is the bottom "curtain I cut out" I later welded spikes to it so it remains stayed put.

[TJS]

More. I cut out some small patches as well. Skimmer plate and return doubler plates. Note: pics are not in order.

[TJS]

Did some internal landscaping and started prepping for the liner. We decided to remove some sand and use the foam cove method. We also used some wiz bang mat but who knows if it just a gimmick.

Take note of this pic. The small vertical patch is troubled waters. Not pun.
The long curtain has spikes welded to it and hammered into the ground to give it some support as the track on the bottom also had to be cut away.

[TJS]

One of the post bases had to be remade. Cut it out and welded tabs on it for the screws. Also another post was in need of repair. There are plastic covers over this area so you cannot see the repair.

[TJS]

Got the liner in and added some water. Used my feet and a little side jumping movement to get the wrinkles out of the bottom. Having never done this before it came out really good.

[TJS]

Here is the trouble. With the pool a little over half full this patch was bowing out really bad. So bad that I was afraid the liner was going to be cut. I had to pump the water out ASAP to re do this patch. This caused a full day set back. During a heat wave this is not what you want to be doing.

[TJS]

I also am painting and have to repair one of the top rails.

[TJS]

Back to the problem patch. I had to drain the pool down pretty far. Cut a new larger patch to strengthen the wall and not cause further problems. Live and learn. At this point I was worried as the liner looses it elasticity when exposed to the sun for a long time. At least that is what a YT pool guru said. I had no issue but was working as fast as possible,

[TJS]

Update:
Here is where I am at right now. Pump is hooked up and pool is functioning. Kids have swam in it. I am finishing up sanding and painting the top rails and getting them installed. along with the plastic covers.
I also dug all the dirt around the outside perimeter or the pool to where the dirt line is now below the track. I plan on getting some stone for drainage. I still have at least a full day or two ahead of me to get this thing done.
Many people I spoke to that have this issue gave up and took their pool down. Not me, I was determined to fix this thing on just the essentials. I could have not done it without my plasma table. I know this will not last another 10 years but if I get a few seasons out of it I am good with that.
I will post more pics of the completed project when I finish.
T.J.

[kicktillmonday]

Awesome! Very impressive fixes, I am sure you will get a few more seasons out of it now I cannot begin to list off all the stuff I have been able to fix with the help of my table. An invaluable tool no doubt. Great work.

[tnbndr]

Nice job

[adbuch]

Nice work TJ! Thanks for sharing the photos of your progress as you worked thru these issues.
David

[TJS]

Thanks all. It is finally done. 2 tons of stone. Lots of shoveling. This hard work paid off. Pool is so far so good. I could not have done it without my cnc table. Total cost 940.00

[adbuch]

TJ - that really looks great! Wish I had that in my backyard here in Tucson.
David

[kicktillmonday]

Very nicely done TJ! Looks mint, not a bad price at all and it looks like you have a VERY happy customer

[TJS]

Just a note. I contacted a few local pool companies and all they wanted to sell me was a complete pool. I told them what I wanted to do in regards to making steel patches and such. They told me it won't work. I never take no for an answer and never say it cannot be done.