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I am curious - do you think the shell has changed shape since the day it was delivered, or was it just made this way?The reason I ask is simply that if the tub is made this way, the replacement may very well be the same. I suppose you could go to the dealer with a straightedge in hand and look at a similar model.Hope it comes out ok.I think it was like that from day 1. Each corner varies from 5/16" ~ 5/8". I only noticed because of the steam leaking out and Northwoodsdipper's thread. When looking at the underside of the cover, you can see that their are no marks on the corners of the cover where it would touch/seal to the corners of the tub. A friend has the same Coast tub without the lounger and his is dead level.I checked my concrete pad and it's level on all 4 sides and there are no cracks around the parimeter of the pad. (There goes the first excuse that the dealer gave me via phone). 8-)
I can see the issue you are concerned with and I understand why you're getting icecles. What I also see is that your spa is recessed into the deck. Any decision regarding the spa could require replacement, but it will obviously be hindered by removal. Have you made any provisions for the removal of the spa from it's setting (open on one side to slide out).First, let's see what Coast comes up with, replace or not. Assuming they would replace it, how would you remove the spa and install the new one, and who would be responsible for those expenses, you or Coast? (You, I think) IF a manufacturer replaces a spa, it does not mean that they will pay freight, delivery or removal of the spa. Just a heads up, but, I would list and consider all remedy options available and their related expenses to you. A simple fix (such as a space filler, or strapping the cover down, bending the cover foam) may be an inexpensive solution where replacement may come at you with some $ signs.
Should be interesting to see how this all plays out.You say your friend has the same spa, without the lounger? Then it's a DIFFERENT spa, made in a different mold. I don't believe I've ever seen a spa "warp" in the way it's being suspected yours is, and am more prone to thinking the mold the shell was made in isn't flat. I could imagine that if this is the case, the manufacturer may claim that your spa is not having a warranty problem, that's the way it was made.I had a manufacturer legally deny a warranty claim made by me many years ago, saying that in fact the problem was not a manufacturing defect (which would have been covered under warranty) but was actually a "design defect", which was NOT covered by warranty............ they went out of business shortly there after Just to play devils advocate, and maybe give you something to think about for compiling some ammo........ If their mold isn't flat and ALL of this model of spa are coming out this way...... If you looked at one before buying, and it too had this same drop on the corner , well, you bought exactly what was shown to you..... I doubt it says anywhere that you'd be getting a spa with a perfectly flat top-edge and the cover would seal perfectly to it.
It's not the mold. The spa is sagging in the corners from lack of structural support in that area.
I don't believe I've ever seen a spa "warp" in the way it's being suspected yours is, and am more prone to thinking the mold the shell was made in isn't flat.