Return Opening Rusted

by Jeff
(Ne Ohio)

I recently purchased a home with an above ground pool with a deck all around it. It seems that the pool had a hole so I purchased a new liner and the guy came to install it and found that the return hole on the wall is rusted and is no good.

He mentioned that he has seen a return that is larger than your standard return but doesn't know where they are available from. Would you have any info on this? Please help!! Jeff


Hi Jeff. I have seen a few over sized returns but I would have no idea where to find one. I would not even bother trying, they were not that great of a product, and fixing what you have is so much easier.

The best method is to tape a sheet of flat metal over your existing return opening, from inside the pool, and then to cut a new opening.

Doughboy has used skimmer and return plates for 40 plus years now so they are perfectly save. Way back when, thru wall skimmers were not standard equipment, so they provided plates to cover the skimmer and return openings. They still do on larger pools that require two walls. They both have openings, as well as plates to cap the openings off, the end not being used for the filter equipment.

Any flat piece of steel or aluminum will work. I have used aluminum flashing, metal flat stock from Home Depot, cookie sheets cut to size, and once in a pinch a beer can, also cut to size.

You tape the metal to the inside of the wall with duct tape. Run the side tapes up and over the wall, this helps to hold the metal in place until the water fills and it is permanently attached, due to water pressure.

Cutting a new opening is easy. A Hayward fitting takes a 2 1/2" opening and a Doughboy take a 2" hole. You use a sharp hole saw, cut the new opening in a good section of wall, smooth it out with a hammer and chunk of wood. You can even coat the area with clear finger nail polish for some added protection against future rust.

All that remains is redoing the plumbing. With a flex hose that's pretty easy. The new hole can easily be made within working distance for your existing hose. With solid plumbing you will need a little pipe and maybe an angle fitting or two. But it is all minor stuff.