Hints and Tips to alternately repair your rotating return unit, with DIY parts, after your warranty is expired or you accidentally damage it:

• If you break and crack your case you might want to try a case from Serpac, S-Series Model #173 Black, dimensions are critical so refer to your old case.
• In the situation where your case is broken and/or corrosion of motor and drive mechanism scraps the unit, refer to the photo for example replacement drive mechanism parts.
• If your mounting brackets break off you might replace them with 90° PVC extrusion angle, .205" thk x 1.50" x 1.50". See photo for example. If you install nylon screws wet with epoxy, they won't work loose.

DIY Case and Mechanism Dimensions	DIY Replacement PVC Brackets

• If your motor burns out and you would wish to try out an alternate power source, use Hurst Gearmotor 6Z535, available from Grainger. (This is a 1 rpm model) See photo for example.
• This selection of motor will necessitate a DIY motor mount due to different motor attachment points. See example photo. Easiest rework is to order a motor from OEM or unit manufacturer.
• Alternate motors could be:

Hurst 1 rpm - Model 3002-001 (Grainger 6Z5535)
Hurst 2 rpm - Model 3002-003 (Grainger 6Z5536)

Crouzet 1 rpm - Model 82 354 118
Crouzet 2 rpm - Model 82 354 119

Hansen PM AC Synchron or Synchron Motors

Autotrol 1 rpm - Model 150-1308 (Sea-Swirl Oem Motor)

Hurst DIY Replacement Motor	DIY Replacement Motor Mount

• The electrical wire to feed this unit should be a 3-wire grounded lead with molded 3-prong plug, attach ground wire to metal motor mount plate for a good ground connection. See photo for example.
• Add a 110vac rocker switch to enable motor to be shut down thereby stopping the unit's elbow from rotating when feeding or servicing. See photo for example.

DIY Motor Ground Lead Attachment	DIY On/Off Switch Installation

• If drive linkages should eventually wear out or work loose, they can be handily replaced with same parts as supplied by OEM. In the case where these parts are unavailable, alternate drive mechanism parts may be DIY fabricated using Nylon and PVC stock material. See photo for example.
• If your outlet elbow cracks after long-term usage and wear, you may opt to replace it with 90° black PVC elbow from Customaquatics, P/N pf-SP406-010B for a 1.0" i.d. See photo for example.

Alternate DIY Drive System	DIY Replacement 90° Elbow Fitting

• All or any broken nylon hardware may be replaced with a wide selection of items from your local corner hardware store or Micro Plastics Inc.
• In the event your unit begins to leak after 2.5 million cycles, which is equivalent to running 24/7 for 5 years, the O-Rings may require replacement in which case Viton O-Rings would be recommended. Visit Marco Rubber and Plastics Inc or your local hardware for replacements, ensuring to state O-Ring c.s (cross-section) and i.d (inner diameter). In the occurence that your O-Rings are too worn to measure, verify the o.d of your inner fixed shaft and the i.d of the outer fixed shaft with a precision tool such as a dial vernier. The grooves for your O-Rings should match one of those in the table for O-Ring Groove Design, allowing you to determine which O-Ring it was you originally had in your unit.
• Should you strip, break or loosen the rotating shaft assembly while trying to change the inlet fitting, you're now looking at having to completely disassemble your unit. In the occurence that it must be replaced due to excess damage, an alternate would be to DIY a new rotating shaft assembly as follows:
• Use a 3/4" CPVC male thread female slip fitting modified as per example photo.
• Cut a piece of 3/4" CPVC pipe as per example photo.
• Cut (3) or (4) O-Ring grooves in 3/4" CPVC pipe as per example photo.

DIY 3/4" CPVC Fitting Modification	DIY CPVC Mod Fitting and Collar
DIY Inner Pipe "O-Ring" Groove Cutting	DIY O-Ring Groove Cutting Setup

• Assemble modified fitting and pipe together as per example photo and insert in case with inlet fitting as per example photo.

DIY Assembled Inner Pipe with Fitting	DIY Inner Pipe Assembly into Case
Inlet Fitting to DIY Inner Pipe Fitting	Barbed Inlet Fitting to DIY Inner Pipe

• Re-use outer shaft assembly or fabricate DIY outer shaft with Sch80 molded PVC pipe nipple. Attach a DIY PVC bellcrank as per example photo.
• Assemble DIY outer shaft assembly to DIY inner fixed shaft assembly as per example photo. Use a non-toxic food-grade silicone lubricant such as Dow-Corning 111.

DIY PVC Outer Pipe with DIY Bellcrank	Install DIY Outer Pipe to Inner Pipe

• Secure DIY outer shaft to DIY inner fixed shaft with CPVC collar as per example photo.
• Attach drive mechanism to DIY bellcrank as per example photo.

Install DIY Collar on DIY Inner Pipe	Secure DIY Collar with Nylon Screw
DIY Drive Link to Bellcrank Attachment	DIY Drive Linkage Overview

• Before final closing, test assembled unit to ensure all mechanisms operate freely.
• Close unit, install 90° elbow while ensuring proper alignment, and return to operation.

Close-out DIY Unit and Install Cover	Install Cover and Tighten Screws
Install 90° PVC Elbow and Align on DIY Shaft
	Please be advised that this was a personal project for the enjoyment of learning and working with my hands. Any disaster, damage, death or any other incident derived from someone attempting to reproduce and/or operate this unit is solely their own responsibility. If you are not comfortable working with water under pressure or electricity or both, do not attempt this project, or at the very least ask the assistance of somone who is skilled or experienced in the art of DIY.