Spa with integrally molded working components and method for making same

A spa comprising:

• a a water pump;
• b. a water heater;
• c. spa working components including:
• a pump inlet line having a first end connected to a water inlet for said pump;
• a pump discharge line having a first end connected to a water discharge for said pump;
• and, a pump/heater housing having a wall portion and an open portion, said water pump and said water heater being located within said pump/heater housing;
• d. an integrally formed spa body made of expandable foam, said spa body encasing at least a portion of each of said spa working components, said spa body having a floor with an outer periphery and a peripheral wall extending vertically and upwardly from said outer periphery, said peripheral wall having an inner side and an outer side;
• e. a waterproof liner coextensive with said floor and an inner side of said peripheral wall, said liner forming a hydraulically impervious seal therein;
• f. an inlet fitting and an outlet fitting, said inlet and outlet fittings being installed over an inner side of said liner in predetermined locations and being in hydraulic communication, respectively, with a second end of said pump inlet line and a second end of said pump discharge line.

A method for making an integrally molded spa comprising the steps of:

• a. providing a female mold;
• b. preassembling spa working components, including a water pump inlet line having a first end and a second end, and a water pump discharge line having a first end and a second end, and installing them in spaced relation over and in spaced relation from a cavity side of said female mold;
• c. providing a male mold having a cavity side;
• d. installing said cavity side of said male mold over said cavity side of said female mold, defining a foam cavity between opposing cavity sides of said female and male molds and fully enclosing said spa working components therein;
• e. introducing expandable foam into said foam cavity, integrally forming a floor and a peripheral wall of a spa body while encasing said spa working components in foam;
• and,
• f. removing said female and male molds from said spa body.