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Thread: How to fix a cracked pump housing

  1. #1
    Junior Member carli's Avatar
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    How to fix a cracked pump housing

    This is what I did today. There was a crack line in my Hayward pump housing. Epoxies and other bonding
    products won't work with this type of plastic and in this high pressure environment. I was not feeling like
    spending $180 to replace the housing so using plastic molding technique with a soldering iron I took care
    of the problem. " This tool needs to be 60 watts minimum because you will be working on hard plastic". You need to take
    out the motor because the crack need to be fix on both sides. Look at the photos. Wear a mask, dangerous fumes.
    Attached Images Attached Images
    13,500 gal, IG plaster, 1 HP Hayward, 36 sqft Purex DE filter
    Jandy NL valve, Hayward multiport valve

  2. #2
    Senior Member In the Industry

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    Re: How to fix a cracked pump housing

    just like a hot knife

  3. #3
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    Re: How to fix a cracked pump housing

    What model housing do you have? I just ordered a new one because I'm going to 2" which will leave me with my old one spx 1600aa. If your repair doesn't work I'll be more than happy to work with you if you need it before it goes to the land of ebay
    "There are no bad days, just some better than others"


    18k, Ig Vinyl, 3/4 us motors, Hayward sand filter, quickpure3 ozone generator

  4. #4
    Junior Member carli's Avatar
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    Re: How to fix a cracked pump housing

    Thank you, but this repair is working perfect and in the case it didn't you can cut
    a small piece of metallic screen placed on the repair spot and using the soldering iron
    it will melt the plastic surface and incrust itself into it for added strength.
    13,500 gal, IG plaster, 1 HP Hayward, 36 sqft Purex DE filter
    Jandy NL valve, Hayward multiport valve

  5. #5
    Senior Member linen's Avatar
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    Re: How to fix a cracked pump housing

    Nice job carli

    Let us know if it holds up.
    TFP Moderator who uses Pool School and my TF100 test kit along with PoolMath for my: Round 11K gallon AGP with deep end, 20" sand filter, Matrix 1hp 2spd, 6 2ftX20ft solar panels (and solar cover!), Intex SWCG (copper bars disconnected) and a Rubadub hot tub (chlorine). The SLAM process is not finished until: 1. CC < 0.5 ppm, 2. An OCLT < 1.0 ppm and, 3. The water is crystal clear.

  6. #6
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    Re: How to fix a cracked pump housing

    I know you said epoxy don't work, but have you tried JB Weld? This stuff is a miracle worker. My ex repaired a hole in his car radiator with it and it lasted another 2 years. No kidding. And I fixed our washing machine tub that got holes in it from a necklace that scraped the sides until it wore it down. That was, Oh gosh, probably 15 years ago and I'm STILL using that machine. But, I don't recommend the "4 hour set" kind. I would go with the one that requires atleast 24 hours.

  7. #7
    Junior Member carli's Avatar
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    Re: How to fix a cracked pump housing

    Quote Originally Posted by mommabeans
    I know you said epoxy don't work, but have you tried JB Weld? This stuff is a miracle worker. My ex repaired a hole in his car radiator with it and it lasted another 2 years. No kidding. And I fixed our washing machine tub that got holes in it from a necklace that scraped the sides until it wore it down. That was, Oh gosh, probably 15 years ago and I'm STILL using that machine. But, I don't recommend the "4 hour set" kind. I would go with the one that requires atleast 24 hours.
    I tried the JB water weld without success maybe is the extreme pressure of water that eventually pulls it off. I guess you can try but after I did the plastic welding with soldering Iron I fix it and is working fine now.
    13,500 gal, IG plaster, 1 HP Hayward, 36 sqft Purex DE filter
    Jandy NL valve, Hayward multiport valve

  8. #8
    Senior Member NoFear95's Avatar
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    Re: How to fix a cracked pump housing

    Fantastic! My father ended up replacing his for a crack about a year ago. I love fixing these types of things myself. Great find with pictures!
    IG, 18K gallons, 100' Perimeter, 565 SF surface area, 980sf interior area, Max Length -36', Max Width - 16', Pentair 520 Clean and Clear Cartridge Filter, Stenner Chemical Injection System (Chlorine, Acid Coming Soon) , Pebble Tech - Blue Granite, Pentair variable speed filter pump, Zodiac MX8 Cleaner, Multi-Colored LED Lighting, Travertine coping & Decking, Boulder Water Fall....

  9. #9
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    Re: How to fix a cracked pump housing

    Quote Originally Posted by carli
    This is what I did today. There was a crack line in my Hayward pump housing. Epoxies and other bonding
    products won't work with this type of plastic and in this high pressure environment. I was not feeling like
    spending $180 to replace the housing so using plastic molding technique with a soldering iron I took care
    of the problem. " This tool needs to be 60 watts minimum because you will be working on hard plastic". You need to take
    out the motor because the crack need to be fix on both sides. Look at the photos. Wear a mask, dangerous fumes.

    are you saying you just melted the crack together, did not use any other plastic , just melted the inside and the outside together????
    how does that stand up to water pressure, isn't the rest of the housing more thick than the resulting repair line.

    it looks like I could do that, but I am not sure what other stuff you used or exactly what the term "using plastic molding technique" means."
    I don't want it to explode on me when I am done
    confused.

  10. #10
    Junior Member carli's Avatar
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    Re: How to fix a cracked pump housing

    Quote Originally Posted by trash
    are you saying you just melted the crack together, did not use any other plastic , just melted the inside and the outside together????
    how does that stand up to water pressure, isn't the rest of the housing more thick than the resulting repair line.

    it looks like I could do that, but I am not sure what other stuff you used or exactly what the term "using plastic molding technique" means."
    I don't want it to explode on me when I am done
    confused.

    Yes, I just melted the crack together with the soldering iron without using any other plastic. In the first photo you can see
    the first step. Melt that line crack, the plastic will melt to the sides, then melt each side again to the inside of the crack. You need to work both sides of the crack. I did this six months ago and the housing is still working perfectly.

    Don't waste your time with epoxies and other stuff this is the only way because of the pressure. I did this really quick and believe me it is a super strong bond.
    13,500 gal, IG plaster, 1 HP Hayward, 36 sqft Purex DE filter
    Jandy NL valve, Hayward multiport valve

  11. #11
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    Re: How to fix a cracked pump housing

    Urethane Supply company makes a produce called Fiberflex that will bond with most plastics and can bring the strength back to a broken piece if your worried. I use there plastic welder with it, but I works and works well.

    The main advantage is that after you push existing plastic together (like Carli did) you can then add material on the outside to ensure permanent fix.

    Carli, great job, this should give many people confidence to do this repair themselves and save lots and lots of money.

    An alternative to this "self" repair would be to take the empty plastic shell to their local auto body shop or specifically anyone who repairs bumpers. This is basic plastic bumper repair 101.

    Bob E.

  12. #12
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    Re: How to fix a cracked pump housing

    I had a crack in my pump housing and fixed it with JB Weld AND a strip of fiberglass cloth on the inside of the housing. I applied a bit of JB Weld around the crack (after carefully sanding off the white "crust" on the inside of the pump housing) and then laid the fiberglass strip in place, making certain that it extended at least a half-inch beyond the crack in every direction. Then I added another thin layer of JB Weld, so that the fiberglass cloth was fully saturated. It's been working for a year or so.

    I had previously tried just using JB Weld on the outside of the crack, but the pressure would spread the crack and split the JB Weld in just a couple of days.
    26,000 Gallon Gunnite IGP
    2 HP Challenger High Head Pump
    60sf Nautilus DE filter
    Polaris 280

  13. #13
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    Re: How to fix a cracked pump housing

    Bump to say a great big thank you to Carli for starting this thread. Based on his original post above, I tried the same plastic welding technique for an almost identical housing crack. I'm happy to say I also got the same results as Carli: my pump is working again! A little elbow grease, pvc work and basic welding and about $30 in materials, I can avoid or at least postpone having to splash out hundreds of dollars on a new pump.

    For the benefit of others who may face similar situation in the future, I'll add a few photos and comments.

    My pump would not prime when the pool store folks came to open the pool last week, and a cracked pump housing was discovered.

    Before photos, from the front and from the back:







    And the "after" photos:







    To do this, I bought a cheap welding iron from Harbor Freight for just over $15, and first tried just welding from the front only with the pump in place still connected to the plumbing. I did this because I am no longer young and flexible enough to contort my body in such a way as to reach the inside of the back of the pump to weld, even after the motor had been removed. The front weld seemed to work at first but then after a few minutes it gave out, so I decided that I might as well cut the pvc plumbing lines and remove the pump to access the back, especially since I would need to change the plumbing anyways if I had to replace the pump.

    Once I cut the pipes and disconnected the pump housing (without motor), I was able to position things somewhere that I could comfortably access and weld both front & back. The hardest part was reassembling the new plumbing, but that was going to have to happen regardless, so I figured I had nothing to lose by trying the welding. Worst case scenario was it wouldn't work and I would be out the cost of the welding iron and the time and effort invested.

    Fortunately for me, it did work. My pump is back to working normally, and the cost of supplies was less than $30, which I much prefer to the $1,200+ quote from the pool company for a new variable speed pump. I may well get a new pump sometime soon anyway, but I won't have to do so in a rush and under a time crunch.

    Thanks again, Carli. You da man!
    25,000 gallon, vinyl IG, 1 HP AO Smith pump, Hayward S-240 sand filter, SWG, Polaris Pool Cleaner 280

  14. #14
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    Re: How to fix a cracked pump housing

    This sounds much like my problem. I can't see the cracks on the bottom of the housing but when it's slightly picked up, I can see the water come out in what looks like spider cracks. I have the pump bolted down. Does epoxy not work at all or will it buy me some time? Also, I can't see the pictures Carli has posted. Anyway to view them in case I decide to try this route out?

  15. #15
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    Re: How to fix a cracked pump housing

    I didn't try the epoxy, because (1) I heard from several sources it wouldn't work with the pressure; and (2) it wasn't hard at all to just try welding the plastic. If welding works, it's superior to epoxy.

    You will no doubt need to unbolt the pump and be able to disconnect the plumbing so that you can access the pump and do any welds/repairs necessary. Even if that doesn't work, you'll need to remove the old pump anyways, to replace it, so give it a go. Don't fret it. You have nothing to lose. You can always try epoxy later if you want.

    Good luck.

    P.S. Not sure why Carli's photos wouldn't be showing for you. I can sure see them. In any event, they look much like mine so don't sweat it.
    25,000 gallon, vinyl IG, 1 HP AO Smith pump, Hayward S-240 sand filter, SWG, Polaris Pool Cleaner 280

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