Kohler Acrylic Shower Base

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Rmat3

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I recently installed a 30" x 60" Kohler Rely shower pan. The instructions call for eight mortar mounds, each about 5 inches in diameter and 1 to 4 inches high. The manual notes that the base isn't designed to sit perfectly flat, and the mortar is intended to support it at key contact points.


I used MAPEl 4-to-1 mortar, mixing it on the dry side as recommended. The mounds were placed over cured MAPEI self-leveling cement, and I let everything sit for 5 days to fully cure.

The majority of the pan feels solid underfoot. However, when there is not weight on the pan the front left corner does not feel as if it adhered properly to the pan as there is some give followed by a hollow tap sound when I tap my heel on it. When I’m already standing on the pan it sounds and feels solid.

I have attached photos I took from between the stud wall of the underside of the pan. For the most part it feels solid with weight on top. My concerns are that some of the mounds didn’t cure solid and have cracks. I considered lifting up the pan and placing a generous amount of thinset on top of the motor mounds and resecuring the flange. Thanks in advance for any advice or recommendations you can provide.
 

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