Build A Hot Tub Cover In 7 Steps

A hot tub cover serves may purposes including keeping the water clear of leaves and debris, preventing animals from using it as a water source and to deter children from taking an unsupervised dunk. Hot tub covers are not meant to hold the full weight of an adult and you should not store things on top of them. You can build a cover for your hot tub wth a moderate knowledge of how to measure and use simple tools.

Step 1: Measure Twice, Cut Once

Measure the size of your hot tub. You will need exact measurements of the whole top of the hot tub not just the area where water is exposed. You are going to divide the measurements directly in half and transfer the measurements to each piece of plywood. If your hot tub is small, you may be able to use one piece of plywood with the whole measurement, then cut the piece exactly in half.

Step 2: Time To Make A Hinge

Using a 1/8-inch wide piece of the vinyl, make a strip that is the length of your plywood. Attach only 2 inches of each side to the board to allow for leeway when opening the cover. Use the washers and screws every six inches on each side of the vinyl to create a hinge on the lower side of the cover.

Step 3: Centering The Insulation

Use the glue to attach the insulating foam on the bottom of your cover. The foam will be covered with the marine vinyl in the next step.

Step 4: Vinyl Power

The vinyl will protect the wood from the hot wet steam that the hot tub produces, keeping your cover from being bogged down with moisture. Measure out how much vinyl that you will need using the plywood as a template, 4 to 5 inches overage on each side should be a sufficient measurement. Lay the plywood in the center of the vinyl and wrap the vinyl around the edges, securing it every 3 to 5 inches with the staple gun. The top is the side with the staples showing. Do not worry, the foam padding and fabric will cover this.

Step 5: Make It Pleasing To the Eye

Use your staple gun to attach a 5-inch strip of fabric along the outer edge of the plywood, 2  inches from the edge. You can get fancy and make pleats if you choose or just make it straight around, tucking in the edges. Think of it as a skirt. You might need to use more than one strip to make it all the way around.  

Step 6: Fabric Time

Measure your padding to the exact measurements of your plywood and cover with the outdoor fabric. Use the spray on adhesive and make sure that there are no wrinkles, the fabric should wrap around the padding with about four inches on the backside. Secure the padding to the top of your cover with a strong adhesive.

Step 7: Attach the Handles

Attach two handles on each side of the cover. Measure so that they are the same distance from each other. Attach the handles through all layers of the cover. Place on top of you hot tub and enjoy.

Your new hot tub cover will insulate the water, allowing it to retain more heat. You'll be able to keep the water at your ideal temperature while saving on your energy bills.