Crafting Comfort: A Guide To Creating Your Own Spa Cover

how to make a spa cover at home

Making a spa cover at home is a great way to save money and ensure your hot tub is protected. There are many ways to make a DIY hot tub cover, and the right type of cover depends on several factors. Before you start your project, you should consider who will be using the spa, the climate you live in, and your budget.

Some common materials used for DIY hot tub covers include wood, plastic tarps, marine vinyl, Sunbrella fabric, and neoprene. It's important to consider the pros and cons of each material and decide which one is most suitable for your needs.

When building a hot tub cover, it's crucial to follow the necessary steps, such as measuring your hot tub, cutting and preparing the materials, assembling the cover, and ensuring a proper fit.

By making your own hot tub cover, you can save money and customize it to your specific needs. However, it's important to keep in mind that DIY covers may not provide the same level of heat retention, security, and durability as professionally made covers.

Characteristics Values
Materials Wood, polystyrene foam boards, heavy-duty adhesive, exterior paint, hinges, screws, tarp, glue, staples, insulation, duct tape, fibreglass, epoxy, aluminium, reflective material, marine vinyl, cedar slats, Volara foam rubber, fender washers, deck screws, marine vinyl, Sunbrella fabric, neoprene
Tools Jig saw, knife, hacksaw blade, packing tape, sandpaper, staple gun, dough roller
Cost $150-$1,500
Time A few hours to a few days
Difficulty Medium to hard
Pros Lightweight, easy to use, saves money, can be customised
Cons May not be suitable for outdoor use, may not hold heat efficiently, may be challenging to secure, can warp, may require a spa cover lift, can bend and allow rain/snow into the spa

shunshelter

Measure your hot tub

Measuring your hot tub is a crucial step in making a spa cover at home. Here are some detailed instructions to help you measure your hot tub accurately:

Measure the Dimensions:

Start by measuring both the inside and outside dimensions of your hot tub or spa shell. It is important to measure twice to ensure accuracy. Draw a guide on paper to help visualise the measurements. Your DIY spa cover should be slightly larger than the rim of the spa to prevent it from falling in. Therefore, consider adding an extra 0.5 inches to 1 inch to both the length and width of your measurements. This will allow for easy removal and prevent a too-tight fit, which can make it difficult to remove the cover.

Measure the Skirt Length:

The skirt is the overhanging flap that prevents heat loss around the edges. Measure the length of your existing cover's skirt, or a standard skirt length of around 4 inches is recommended. If you have a wooden ledge or cabinet around your hot tub, ensure that the skirt length is not too long to avoid problems with the cover fit.

Measure the Radius:

The radius is the measurement from the start of the bend to the imaginary point of the corner if the hot tub cover was square. This can be tricky to measure, but a carpenter's square or a homemade version made from strong cardboard can be used. Remember, the smaller the radius, the more square the corner of your hot tub cover will be.

Specially Shaped Covers:

If your hot tub has a unique shape, such as a rectangle with rounded corners, an octagon, or an ellipse, you will need to take additional measurements. For rectangular hot tubs with rounded corners, you may need to use a jig saw to cut the radius curve in the plywood or other covering material. For octagonal hot tubs, measure the length of one side and the length of each section of the octagon. If your hot tub is elliptical, take two perpendicular measurements and add a small amount of wiggle room to each.

Compare Measurements:

Finally, compare your measurements with stock covers or custom cover options to find the best fit for your hot tub. It is important to get a cover that fits well to maximise energy efficiency and minimise heat loss.

shunshelter

Cut the materials

Now that you've measured your hot tub, it's time to cut the materials.

For square hot tubs, you can get away with less cutting of the plywood and foam boards. In fact, you might not even need to cut them at all. If your hot tub has rounded corners, octagonal cuts, or is circular, you'll need to break out the jigsaw to cut the radius curve in the plywood. You can cut the foam with a sharp kitchen knife or a hacksaw blade.

After cutting both pieces, lay them on top of each other to remove any rough edges and ensure they are almost exactly the same size.

If you're using wood boards, cut them long enough to overlap each side of the hot tub by about an inch. You can also cut the wood to size and sand the boards smooth.

If you're using a tarp, cut it several inches bigger than your hot tub's dimensions. Cut it twice as long as you need, plus 3 inches on each side, so you can fold it over. The width should be the width of the hot tub, plus several inches on each side.

If you're using cedar, rip the cedar 2 x 4s in thirds to 2" x 1.3" to make 28 slats, and trim them to be 3" wider than your tub and cover edge.

If you're using marine vinyl, cut it to size, leaving enough to reinforce the edges.

If you're using a regular tarp, cut the tarp to have at least 3 inches all the way around to fold over the top of the insulation.

If you're using Sunbrella, cut it to size, or to whatever pattern you desire.

If you're using neoprene, cut it to size.

shunshelter

Wrap the foam in heavy plastic

Wrapping the foam in heavy plastic is an important step in making a spa cover at home. This step helps to protect the foam from moisture and water damage, as well as providing a layer of insulation to help retain heat in the spa.

To start, you will need a roll of heavy-duty plastic sheeting, such as painter's plastic, which is at least 4 mil in thickness. This thickness will provide a strong barrier against moisture. You will also need a large roll of packing tape to secure the plastic in place.

Begin by laying the foam board on the plastic sheeting. Cut the plastic so that you have enough to wrap all sides of the foam, similar to wrapping a gift box. You will want to leave enough plastic to be able to fold it over the corners neatly and securely.

Once you have cut the plastic to size, start by folding the plastic over the edges of the foam board, taping it down as you go. Ensure that you pull the plastic taut as you work, wrapping the foam as tightly as possible. This will help to create a smooth finish and ensure the plastic stays in place.

When you reach the end of the foam board, finish wrapping by folding over the final edge and taping it down securely. Go over the entire wrapped foam board, checking that all sides are tightly wrapped and taped. Pay particular attention to the corners, ensuring they are neatly folded and fully secured with tape.

Now your foam board is protected by a layer of heavy-duty plastic, which will help to keep moisture at bay and your spa water warm.

shunshelter

Glue the foam to the wood boards

Now that you have your materials ready, it's time to glue the foam to the wood boards. This step is crucial, as it will ensure that your spa cover is securely attached to the wood base. Here's a detailed guide on how to do it:

Firstly, you'll want to use a heavy-duty adhesive like Liquid Nails or a similar product. These types of adhesives are designed to create a strong, long-lasting bond between the foam and the wood. Apply a liberal amount of the adhesive directly onto the wood boards. Make sure to cover all areas, paying special attention to the edges. You can use a caulking gun or a sponge brush to apply the adhesive evenly.

Next, take your wrapped foam boards and press them firmly onto the wood boards. Make sure the foam is aligned correctly and covers the entire surface of the wood. You may need to use clamps or place heavy items on top of the foam to ensure a tight bond while the adhesive dries.

If you want an even stronger bond, consider roughening the surface of the wood before applying the adhesive. Use 80-grit sandpaper and rub it in a circular motion over the area where the foam will be attached. This creates a more porous surface for the adhesive to penetrate, resulting in a stronger hold.

Additionally, you can reinforce the adhesion by screwing through the foam into the wood. Make sure to use appropriate screws and washers that won't rust, such as stainless steel or rust-proof coated ones. This will provide extra support and ensure that your spa cover stays securely attached to the wood base.

Let the adhesive dry completely according to the manufacturer's instructions before proceeding to the next step. Typically, you'll need to allow several hours for the glue to set properly.

Remember to work in a well-ventilated area when using adhesives, and always follow the safety instructions on the product label.

By following these steps, you'll be able to securely glue the foam to the wood boards, creating a solid base for your DIY spa cover.

shunshelter

Paint the wood and install the hinge

Now that you've cut your materials, it's time to paint the wood and install the hinge. Sand the edges of the wood to ensure a smooth finish and remove any splinters or rough spots. Use an exterior paint and don't be afraid to go heavy on it—you can even paint two coats on the side that faces up. Allow the paint to dry completely before moving on to the next step.

Once the paint is dry, you can install the hinge. You have a few options for this step. You can use several door hinges or opt for one long continuous hinge. If you go with the continuous hinge, use a 1/4" screw in every fifth hole. This will ensure that your hinge is secure and can withstand the weight of the cover.

And that's it! You've completed the five steps to making your own spa cover. All that's left is to put it on your spa and check for heat loss. You may also need to come up with a solution to prevent heat loss through the hinge or certain spots around the spa rim, such as the control panel area. If you have a cover lifter, you may be able to connect it to your new spa cover. Enjoy your DIY spa cover!

Frequently asked questions

You will need polystyrene foam boards, heavy-duty adhesive, plywood boards, exterior paint for wood, continuous hinges and screws, a tarp, glue, staples and staple gun, insulation, duct tape, and sandpaper.

First, measure your hot tub and cut the materials to size. Then, wrap the foam in heavy plastic and glue it to the wood boards. Paint the wood and install the hinge. Finally, put the cover on the spa and check for heat loss.

Making your own spa cover can save you money, but it may not hold heat as well as a professional cover and may be difficult to secure.

Written by
Reviewed by
Share this post
Print
Did this article help you?

Leave a comment