cutting larger return

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scout123

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Feb 18, 2018
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Northwest GA
I'm currently installing my first AGP, and have purchased the Intex sand filter/pump. I want to use the larger return and strainer output (think that's what they're called), by cutting out a larger hole where the current connections are. Can I do this with the pool empty or do I need to fill it part way first? I've read so many posts on cutting for an in wall skimmer and know the pool needs water to stretch the liner before cutting, but can't find anything on cutting a hole for the returns/intake. I'll be cutting over the reinforced area. Thanks.

Also, the new pump didn't come with an air jet valve. It's listed as optional on the page listing all the parts; however, it's in the instructions. Do I actually need this?
 
I cut it when the water was a few inches below the hole, to be sure it was stretched out.

Not sure about your pump question.
 
I cut a hole for a in wall skimmer, enlarged my return and inlet holes, all while the pool was completely full. Just get your spouse or a friend to get in the pool with a large mixing bowl held up against the wall. Be sure to put the inside part of the new fitting inside the bowl first. You'll lose the gallon or so of water that's in the bowl, but that's all. Be sure to use a new exacto blade that's sharp and has no dings in the blade. Take your time cutting it little by little and you'll do fine. Make the new hole just a fraction of a millimeter bigger that the part of the fitting that goes through the hole. You want the fitting to slide through easily, cuz if it wrinkles up from being a hair to small, I can leak a little.
 
Okay, thanks. I'll fill it to just under the hole and then cut. Seems like a lot of extra work to fill it up all the way and then cut, so hopefully this will be fine. Planning to fill and cut either Fri or Sat...can't wait!!
 
The most important part is to go slow and make careful, intentional cuts. You don't need a surgeon's hands, but just don't try to rush through it.
 
scout123 said:
Thanks. Will definitely take my time, and getting a new blade to use too. Nervous, but ready to get this thing going :) Seems I've been planning and doing prep work for months.
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It's definitely nerve wracking the first time, fearing that the knife will hit the vinyl and it'll split all the way down. That vinyl is stronger that you think. And you be happy about the increased flow through the bigger pipes/hoses.
 
Wait until you install a thru wall skimmer. That’s a scary but oddly satisfying cut!
 
kellyfair said:
Wait until you install a thru wall skimmer. That’s a scary but oddly satisfying cut!
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I liked cutting the skimmer hole so much better. Bit scary forcing the first screw through the liner, but when you cut the actual hole, at least you have 16+ screws holding the liner together. Also, you're really just tracing a hole inside a plastic frame, not free hand cutting like you do a return/inlet.
 
Welp, I cut the openings and filled the pool and I have a leak at one of them. After reading through some threads, I think I may have cut it too snug. I had to really work to push the return through the hole. Argggg!! Now I suppose I will have to do the 'bowl' thing, so I can enlarge the hole. At least the other ones seems fine. Guess I know what I'll be doing Friday evening!

Oh, one question...Does a gasket go on the inside and the outside? I only have the gasket on the outside. If I need one for the inside too, where would I get one? A pool store? or would Lowe's or Home Depot have them? Thanks
 

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If you’ve got the return pushed through, you can trim the extra material by tracing your blade around the base of the return. Not sure I explained that in a way that makes sense, so will look for a picture!

I used gasket on inside. If you want one for outside as well, you can buy gasket material at HD or Lowe’s and cut one yourself.
 
137341E9-D9AC-490F-B2DA-9131DFEDCF8E.jpg

Did a screenshot off of a video showing AGP installation, but same concept.
 
I understand what you're saying as far as cutting around the return. I'll do that. I think it would be easier, maybe, and more precise. I was really nervous about cutting the holes, but I think I'm more nervous thinking about having to re cut. I'll move the gasket to the inside. I just thought they went on the outside. Can you tell I'm new to all this! Thanks for you help :)

Saw the pic after posting this. Yes that's what I had in mind after reading your post. I hadn't thought of doing it that way so thank you for the suggestion.
 
If you had to force it through, you definitely cut it a hair to small. When you tighten the nut down on the threads, it'll make small little gaps that water can seep through.

Not sure which return fittings you got, but the Hayward 1.5" return fittings I ordered on Amazon, came with 2 o-ring washers and a cork washer for each fitting. You put one o-ring on the inside of the liner, the other o-ring on the outside of the liner, and the cork washer against the nut (so you don't have to fight to tighten the plastic nut against the rubber o-ring. If you had one of the more expensive pools with the hard pool wall, the 2nd o-ring goes between the liner and wall, and the cork washer goes between the wall and the plastic nut. I think the 2nd o-ring is just an extra layer of protection in case water gets past the first o-ring. With only having 1 o-ring, definitely put it on the inside.

Also, with the bowl method, you'd think at first it'd be hard to hold the bowl against the wall, but all the weight of the water is pushing against it, so it stays on the wall really easily. Just have the person on the inside push lightly against it so it doesn't slide and you should be just fine.
 
The return jet came with the intex sand filter/pump, and only had one gasket. The other, I ordered off Ebay and it's an intex brand as well with only one gasket. I should have researched how to put them on correctly before doing it. My bad! I'm going to get my mom to come over this afternoon to hold the bowl (don't trust my 4 year old! LOL) and hopefully get things fixed. I may run by Lowe's before work this morning and pick up another 2 gaskets, or the material to cut some out so I can go ahead and put one on the outside too. Thanks for all your help.
 
scout123 said:
The return jet came with the intex sand filter/pump, and only had one gasket. The other, I ordered off Ebay and it's an intex brand as well with only one gasket. I should have researched how to put them on correctly before doing it. My bad! I'm going to get my mom to come over this afternoon to hold the bowl (don't trust my 4 year old! LOL) and hopefully get things fixed. I may run by Lowe's before work this morning and pick up another 2 gaskets, or the material to cut some out so I can go ahead and put one on the outside too. Thanks for all your help.
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A local pool supply should have gaskets. Just don't let them test your water LOL.
 
I'm happy to report we have no leaks!! When I got home from work, I noticed a teeny dribble from the strainer intake too so I enlarged the return jet and put the gasket on the inside and I changed the gasket on the intake from the outside to inside and that seems to have fixed it. I got the sand filter/pump running and it's been going for the last 4 hours and no leaks anywhere. Added some salt, and almost finished the landscaping. Happy camper here! Thanks for all the help and suggestions on this.
 
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