I made mine with 3/8" plywood glued (Liquid Nails for foamboard) to 2" pink
No hinge in the middle, I just have 2 halves attached with velcro.
The foam will last a year or two - exposure to UV and spa chemicals.
Covering with a plastic/vinyl/fabric will make it last longer.
The other version I made is a frame of 3/4" pvc pipe, with 45deg elbows (for
an octagon shaped spa) covered with bubble wrap- the kind they use for pool
solar covers. Very light weight but doesn't hold the heat in as well as the
rigid foam one.
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