Claims

1. A spa assembly comprising: a shell portion including a tub portion, a flat upper flange, and an integral spillway, and shaped to be fitted into an existing gunite spa cavity, with the flat upper flange being constructed so as to support the weight of the spa on the rim of the gunite spa cavity; and plumbing elements associated with the shell portion, including at least one suction and one return.

2. The spa assembly of claim 1 wherein the shell portion has a notch in the transition area between the tub portion and the flat upper flange, wherein the notch is sized so as to receive masonry components comparable to those to be placed on the top surface of the flat upper flange.

3. The spa assembly of claim 2 wherein the notch has dimensions from between four to six inches in height to one to two inches in depth.

4. The spa assembly of claim 1 wherein the shell portion includes a vacuum-formed base part and a layer of fiberglass.

5. The spa assembly of claim 4 wherein the vacuum-formed base part is constructed from a material selected from the group consisting of acrylic, plastic, Lucite, resin composite, and carbon fiber.

6. The spa assembly of claim 1 wherein the shell portion is constructed so as to be readily insertable and removable from the existing gunite spa cavity.

7. The spa assembly of claim 1 wherein the suction includes at least one main drain suction, located near the bottom of the shell portion.

8. The spa assembly of claim 1, wherein operating controls are located in a single, readily accessible window region.

9. A spa assembly comprising: a shell portion including a tub portion, a flat upper lip having a top surface, and an integral spillway; and plumbing elements associated with the shell portion, including at least one suction and one return; wherein the shell portion is shaped so that it may be readily installed into an existing gunite spa cavity, with the flat upper lip being constructed so as to allow flat masonry components to be laid/installed directly onto the top surface.

10. The spa assembly of claim 9, wherein the assembly is capable of being installed in a balanced manner, supported by both the flat upper lip and the bottom footwell, without the use of sandbags.

11. The spa assembly of claim 10, wherein the assembly is capable of being attached to an upper rim of the gunite spa cavity by securing elements.

12. The spa assembly of claim 11, wherein the securing elements are bolts.

13. The spa assembly of claim 11, wherein the securing elements are twist-lock fasteners.

14. The spa assembly of claim 12, wherein the securing elements travel directly down through the upper lip and attach to the gunite spa cavity.

15. The spa assembly of claim 9 wherein the shell portion has a notch in the transition area between the tub portion and the flat upper lip, wherein the notch is sized so as to receive masonry components comparable to those to be placed on the top surface of the flat upper lip.

16. The spa assembly of claim 15 wherein the notch has dimensions from between four and six inches in height to one to two inches in depth.

17. The spa assembly of claim 9 wherein the shell portion includes a vacuum-formed base part and fiberglass.

18. The spa assembly of claim 17 wherein the vacuum-formed base part is constructed from a material selected from the group consisting of acrylic, plastic, Lucite, resin-based composites, and carbon fiber.

19. The spa assembly of claim 18 wherein the suction includes at least one main drain suction, located near the bottom of the shell portion.

20. The spa assembly of claim 9, wherein operating controls are located in a single, readily accessible window region.

21. The spa assembly of claim 9, wherein the spa assembly is pre-plumbed and all of the basic plumbing controls are located in a single, readily accessible window region.

22. A spa assembly comprising: a shell portion including a tub portion, a flat upper lip, and an integral spillway, shaped so that it may be readily inserted into an existing gunite spa cavity; and plumbing elements associated with the shell portion, including at least one suction and one return; wherein the shell portion has a notch in the transition area between the tub portion and the flat upper lip, which is sized so as to receive masonry components that provide a matching, transition zone allowing the desired masonry to extend seamlessly into the water line.

23. The spa assembly of claim 22 wherein the shell portion includes a vacuum-formed base part and fiberglass.

24. A method of making a spa comprising: providing a base having a flat upper lip; applying fiberglass material to the base; installing plumbing, including at least one suction and one return, in association with the base; wherein the base, the fiberglass and the plumbing define an assembly; and applying insulating material to the assembly.

25. The method of claim 24 wherein the base is vacuum-formed.

26. A method of making a spa comprising: providing a base having a flat upper lip and an integral spillway; applying fiberglass material to the base; installing plumbing, including at least one suction and one return, in association with the base, wherein the base, the fiberglass and the plumbing define an assembly; and applying insulating material to the assembly.

27. The method of claim 26 wherein the base is vacuum-formed.

28. A method of making a spa comprising: providing a base having a flat upper lip and a water line, wherein the base possesses no orifices within the top eight inches of a water line for the purpose of acting as a skimmer; applying fiberglass material to the base; installing plumbing, including at least one suction and one return, in association with the base; wherein the base, the fiberglass and the plumbing define an assembly; and applying insulating material to the assembly.