Project : Repairing A Hot Tub Tile
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bougieprojects@gmail.com

Step By Step : Each Photo Explained.

01 The Broken Tile
In this photo, you can see the tile that needs to be replaced. Before we start this, we must remove the existing tile and prepare our workspace.

02 Removing The Tile
The tile was bonded on the plywood very well. Unlike a wall or floor, special tile adhesive is used for structures such as this Hot Tub enclosure. It's a real pain in the butt to remove because of it's strong bond, and special care had to be taken to make sure we didn't crack any of the other tiles. We also had to be careful for the metal edging. We wanted no bends or scratches.

03 Cut Out Plywood
The old plywood had to be removed. It was smashed up pretty good and was full of jagged edges. Nothing we could work with.

04 Making It Flush
Debris such as old grout and adhesive had to be removed before we can start to rebuild the tile backing. We want a nice, clean, finished opening.

05 Backing Support
The 2/3 was cut out as well. That is part of the structure that supports the Hot Tub. It has to be replaced to keep the structure as sturdy as it was when it was created. If we did not replace the 2/3, the plywood tile backing we have to install would not be supported well enough and would easily break.

06 Custom Cut
We made this custom groove in the plywood to fit our 2/3 perfectly! We want our frame as flush as possible, not just to use adhesive to balance it out as many other's would do. Pretty fancy work with a circular saw :P

07 New Plywood
A perfect fit. The custom grooved plywood we cut for the tile backing fits like a glove. Half the job is done.

08 Reinforcing
Normally, we wouldn't add this many screws but we wanted to make certain our frame was as solid as possible. As you can see, this area is also the center / face of the Hot Tub. We had to prepare it in case someone was to use it as a seat.

09 Tile Adhesive
Unlike adding tiles to a wall or a floor, for this project we used a special adhesive for tiles. It had to be waterproof and strong!

10 Adding The Tiles
We could not find an exact duplicate of the tile we had to replace. Instead, we decided to go with 9 smaller tiles and create a nice mosaic face instead.

11 Center Tile
This is a nice touch. It's a rustic looking celtic tile that goes in the middle of our mini mosaic. I think it looks real good.

12 Level And Flush
Now that all the tiles have been installed, we check for level and a straight line. We also make sure none of the tiles are deeper or standing out.

13 Adding Silicone
We decided to silicone around the Hot Tub and anywhere else that needed it.

14 Cracks Are Filled
Over time, cracks in your grout can form. In this case, some of the cracks were pretty big. Before water could get in there and cause rot in the structure, and force other tiles to lift - We filled them all.

15 Tub Is Sealed
This Hot Tub is now sealed from top to bottom. Just a note, when you start seeing cracks appear - don't ignore them. They will grow and problems will come. Silicone around all edges and re grout other exposed cracks.

16 Adding The Grout
Now that the adhesive is dry. It's time to apply grout. Just a note, always wait at least 24/hrs for tile glue to dry. This was a small repair, so we didn't wait that long, but it wouldn't hurt to not touch anything for at least 24/hrs.

17 Here It Is
The grout is still wet and will require many washes, but you get to see what the finished project looks like.

18 Finished Project
After a few more washes, you can see the finished project. Even after we leave, after 24/hrs, many more washes should be done. The grout will still be cloudy for days to come.

19 Extreme Close up
Here's a close up look and that nice center piece. I think it gives the mosaic a really nice look.

20 Final Wash
A final tile wash is done to bring out the finish.

Below - Are a few web sites you might find interesting :)