I finally got around to reuploading the photos that were missing in the first post but also wanted to provide an update to where we are at now.
Remember, last year we ended up purchasing an entire new pool on sale as it only cost slightly more than ordering a complete set of replacements for the rusted out legs. Following another users recommendation, we purchased some 2" self fusing silicone tape and wrapped the top and bottoms of the replacement vertical legs. The 2" width allowed us to completely cover the locking pin area at the top as well as the actual edge where the union meets the top of the pole. The horizontal poles already had significant rust forming so we left them as is knowing we'd be replacing those this year.
Fast forwarding to this year, we lowered the water to replace the horizontal poles and found they were all completely rotted and were impossible to remove without shedding shards of sharp rusted metal all over, inside and around the pool area. Here are what these two year old poles looked like:
Because we were worried about the possibility of liner damage due to all of the sharp metal that was lying in the pool after removing the horizontals, we decided to go ahead and use the new liner. We will have no use for spare intex parts after this pool reaches end of life so no sense in saving a new liner that will likely have no poles to setup. We will not be buying Intex products ever again...
When we set everything back up, we were very pleased with how well the silicone tape extended the life of the vertical legs. While some rust formation is present (on the bare metal inside the poles), we estimate that we should get at least two more seasons out of the existing legs (they have been up for a year already). I took the precaution of treating the visible rust with some Loctite Rust Neutralizer, followed up with a couple coats of paint. I added a couple of coats to the ends of the new horizontal poles for good measure and also put a layer of 2" self fusing silicone tape around the ends where the liner rests on the poles, hoping it would seal out some water as well as prevent friction wearing through the coating over time (which we saw evidence of on the old poles). Instead of redoing the bottom of the legs with the self fusing silicone tape, I decided to seal the bottom the legs (where they join the cup) with a bead of silicone caulk. While we had made the tape work, it was awkward to get it to wrap without bunching up because of the flared feet. The tape is perfect for covering the top end and locking pin area however.
I'm still trying to figure out the best way to seal the area where the horizontals fit into the t-joints. My initial plan was to do a silicone tape wrap but the geometry of the area is making me question how well of a seal I'm going to get. Still formulating a plan of action for that...
