Our spa/hot tub is in need of a new cover due to damage from a tree-limb
that fell during a storm. The existing cover is the original that came with
the spa 3 years ago. It was fine but in addition to the new hole, the vinyl
and seams were starting to tear, and it was starting to smell.
We are faced with spending about $300 to order the same exact thing, or more
depending on upgrades to the insulation, vinyl, etc.
So I had the idea to build one using 1/4" plywood to make 2 tapered boxes
that would be hinged in the middle and filled either with sheets of
insulation and expanding foam, or entirely of expanding foam.
My concerns would be the total weight, and moisture. The existing one is
not light, so I want the new one to be about the same weight. And for
moisture, I know it will need extra protection and maintenance.
Comments? Questions? Advice? Ideas? Suggestions?
Thanks in advance,
My original hot tub cover deteriated over time, due to sun exposure and the
neighborhood cats. Here is my solution and it has worked well for me for the
past two years. First part is 3/4 inch thick floating insulation cut to fit
the tub. I got a large chunk of 4 inch thick closed cell styrofoam and
hollowed out the bottom surface to lock on the contours of the top of the
tub surface. I then covered the foam with adhesive-backed fabric (top and
bottom, all the way around). I then sealed the fabric with several coats of
poly. For the very top layer, I use a roll-up type sun shade made from
bamboo (extra weight to keep the foam from blowing off and a cat barrier).
The bamboo shade is held down with small bungee cords.
For each use, I roll up the bamboo and stand it in the corner. (I have some
hooks where I can also use the bamboo for an extra privacy curtain or
sun/wind screen.) Lift the foam top and set it on the bench near the tub.
The floating foam gets draped over the bench back. This may sound like a lot
of work compared to a vinyl cover, but it is fast and easy - even the kids
do this with no problems. My tub may be smaller than yours and my solution
may not be applicable to your situation, but the ply sounds like overkill
and heavy. If you want to continue with a wood solution, explore the
possibility of door skins (light weight 1/8 inch ply).
I live in Maryland and do have (2) new, unused, covers that I would be
willing to let go for "peanuts" ..Came with my hot tub 5 years ago and
was NOT the correct size...manufacturer replaced it with the correct
one ..not once but twice ???? No way was I offering to box the second
one up and lug it to be returned...
One is "about" 72 by 80 the other is about 82 x 82 FROM Memory if
anyone is interested I can actually measure them .... Peanuts BTW
means dirt cheap... suckers take up a lot of room in my basement...
I have a hot tub I built myself and have tried a few different options for
The first was simple tarp. Ugly, and it blew off every time we had a little
wind. Obviously I had to find a better solution.
The second attempt was a simple plywood cover hinged in the middle, and
covered with vinyl. This did not work well at all. The constant heat and
moisture from the tub warped the plywood in many directions within a matter
My current cover is built with a framework of 2x2's, hinged in the middle,
with 1-1/2" thick rigid foam insulation. then everything is covered with
vinyl inside and out. This cover has worked well for the last three years,
but over time the foam itself has absorbed more and more moisture. So, it's
getting rather heavy to take on and off of the tub.
I've been considering rebuilding the cover again, and have thought about
using a single piece of 4" foam insulation, coating that with fiberglass
cloth and resin to keep it water tight. I suppose it would be just as easy
to wrap the foam with plastic, and then cover that with vinyl.
Hot Tub Plans: www.mountain-software.com/hot_tub.htm
We went with the basic spa from Lowe's. It's made by Gatsby but has the
Jacuzzi brand name on it. It has been great for 3 years. Only problem was
a failed temp sensor that they UPS'ed under warranty. It's easy access to
I would recommend a 240v circuit so that you can have heat & pumps at the
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