Mermade 48" x 38" Outlet on Short Side (Chester Replacement), Leaf Only

The Mer-Made 48" × 38" Outlet on Short Side (Chester Replacement) — Leaf Only (also cataloged as the Bare Leaf, Skeleton, or Core Assembly) consists of the fully assembled rigid structural frame, internal high-flow drainage grid, and welded discharge hub on the 38" rail, excluding the fabric filter jacket (cover) and compression sealing collar/gasket.

This configuration is engineered for legacy Chester Products (Chester Pool Systems) commercial vacuum DE filtration systems, integral aluminum/fiberglass surge tanks, and municipal water features. It is specified when existing cloth covers are being reused or sourced from bulk stock, or when replacing cracked, warped, or structurally fatigued PVC frames while maintaining the existing filtration footprint.

Technical Specifications & Scope of Delivery

• Internal open-matrix polypropylene or ABS high-flow drainage grid core

• Molded, gusset-reinforced short-side discharge hub with integral stop shoulder | | Excluded Components | • Fabric filter bag / cloth jacket (Cover Only)

• Top/side closure hardware, laces, or Velcro flap

• High-density felt compression collar or elastomeric sealing gasket |

Structural Design & Internal Core Mechanics

• Long-Span High-Flow Drainage Matrix: A heavy-gauge, open-profile polypropylene or ABS drainage core with rigid cross-ribs. It withstands continuous vacuum draw up to 15" Hg across the full 48" length without face deflection, maintaining unrestricted lateral fluid channels directly toward the 38" short-side discharge hub.

• Torque-Resistant Perimeter Framing: Heavy-wall extruded rigid CPVC/PVC structural channels with thermo-welded corner miter joints. Because the 48" length creates a significant moment arm over the narrow 38" support edge, the frame features internal corner gussets to prevent diagonal racking, twist, or sag under surge conditions.

• Gusseted Short-Side Discharge Hub: Injection-molded, chemical-resistant PVC spud welded directly into the 38" rail. An integrated stop shoulder establishes the proper insertion depth into the Chester manifold receiver and ensures proper compression on the sealing collar.

Physical Dimensions & Weight Estimates

• Individual Bare Leaf Net Weight: Approximately 16.0 to 19.5 lbs (7.3 to 8.8 kg).

• Single Boxed Leaf Shipping Weight: Approximately 24.0 to 29.0 lbs (10.9 to 13.2 kg) in heavy-duty oversized corrugated cartons with edge protectors.

• Master Pallet Lot (10 to 20 Bare Frames): Approximately 260 to 440 lbs (118 to 200 kg) strapped to an oversized 42" × 54" wooden skid.

Field Clothing & Installation Steps

1. Verify Spud Centerline & Handing: Confirm whether the replacement core's outlet position (center-mounted vs. corner-offset along the 38" rail) aligns with the Chester manifold socket layout before fitting the fabric cover.

2. Inspect Frame Surface: Check the outer channel borders and bare grid faces for sharp burrs, rough weld beads, or cracks that could puncture the replacement fabric jacket.

3. Slide the Cover: Slide the replacement fabric envelope over the frame, aligning the pre-cut, reinforced opening around the protruding short-side discharge spud.

4. Seat the Spud Cutout: Pull the reinforced collar of the cover snugly around the base of the outlet hub until seated flush against the molded locating shoulder without bunching.

5. Tension & Close: Pull the fabric taut across the 48" × 38" face to eliminate loose spots or wrinkles, then fasten the closure flap (Velcro seam, clamp bar, or laces).

6. Mount Gasket & Seat: Slide a fresh high-density felt compression collar or elastomeric gasket over the spud against the locating shoulder. Guide the 38" short-side spud into the Chester manifold receiver socket, apply firm pressure to compress the seal, and secure the overhead hold-down beam.