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We had the same thing, the design of the overflow tightening onto the bath was dogshit.
Then we had it again, searched for ages, checked all pipework five times before noticing a little mark on the bath surface. A fucking hole in the bath itself! Someone must have dropped the sharp edged hand shower 🥴
Had to redo the epoxy with a kit off the internet.
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When I was labouring for Fiddy BITD, "someone" (genuinely wasn't me but none of the other trades would own up) dropped a hammer in the brand new bath we were putting in. Because no one owned up there was a long, tense bun fight over who was going to replace it as the homeowner rightfully didn't want a repaired bath when he paid for a new one.
Ours was one of those where you twist the cap on the overflow to operate the plug. It had just deteriorated over time. So replaced with a clicky push plug and all stainless. Getting the old one out was a fucker as the cable access was on the opposite side to where I could reach. Ended up just busting the fucker out. It was going in the bin anyway.
I have also resealed the bath a couple of times now. Mainly twice because the first time was shit, but didn't contribute to any major leaks (to put @aggi 's mind at ease). In the intervening years I got a fuck load more caulking practice in elsewhere in the house so it's a bit better now. I prefer using a blade to get the old stuff out. I've tried the solvent stuff but it always leaves some semi-disolved gunk in the deeper recesses and I'm paranoid that will negatively impact the new stuff from going on properly.
For us it was the overflow, plus ms_com and mini_com running a deep bath. Got a video call while I was in the US for work where water was pushing through the kitchen spot lights, them both standing wrapped in towels crying and the smoke alarm going mad as it had got water in it. Grateful for the fold out bath panels when it came time to replace (plus the 4,000 mile distance when it was actually happening).