How to Order a Hot Tub Cover (Step-by-Step Guide)

Ordering a replacement hot tub cover is simple when you know exactly what information is required. This guide walks you through the process so you can order the correct cover the first time.

Step 1: Measure the Spa — Not the Old Cover

Always measure the spa itself, not the old cover.

Covers shrink, sag, and distort over time. Measuring the old cover often leads to ordering the wrong size.

You will need:

• Length and width (outer edge to outer edge, in inches)
• Corner type (rounded radius or cut corners)
• Skirt length (the vertical drop that hangs down the side)

For detailed instructions, visit our How to Measure a Spa guide.

Step 2: Choose Your Color

We offer 16 vinyl color options, all with built-in UV protection to help prevent fading and cracking.

Color selection is primarily aesthetic. Performance remains the same across all color choices.

Step 3: Select Foam Thickness

Foam thickness refers to the height and taper (slope) of the core.

Most covers we sell use a 4″ x 2″ tapered design:

• 4 inches thick at the center
• Tapers to 2 inches at the edge
• Full 2″ slope for proper water runoff

The taper is critical. Without proper slope, water puddles on top, which adds weight and shortens the life of the cover.

Step 4: Choose Foam Density

Foam density affects insulation value, strength, and longevity.

1.0 lb Density (Standard)
• Lightest option
• Recommended for warm climates
• Common for most Southern California portable spas

1.5 lb Density (Deluxe)
• Increased insulation
• Balanced weight and strength
• Popular upgrade for improved energy efficiency

2.0 lb Density (Heavy Duty)
• Highest insulation value
• Recommended for colder climates or snow exposure
• Standard for in-ground spa applications

Super Foam (5″ x 3″)
• 25% thicker core
• Increased structural strength
• Ideal for extreme conditions or heavy load scenarios
• Heavier than 4″ x 2″ options

Choose based on your climate, how the spa is used, and whether you have a cover lifter.

Step 5: Ready to Order

For spas up to 96″, you can order online directly.

For oversized or free-form spas, call 949-496-2883 for a quote and assistance with measurements.

A properly measured and correctly selected cover will:

• Keep heat in
• Reduce energy costs
• Prevent debris and evaporation
• Improve safety when locked
• Extend the life of your spa

If you have questions, call and ask for Chris. We’re happy to walk you through the process and make sure your order is correct.

Does a Spa Cover Need to Be Cleaned Regularly?

Yes — it absolutely does.

The sun is the biggest enemy of your spa cover. Constant UV exposure, heat, moisture, and chemical fumes slowly break down vinyl over time. Without regular maintenance, even a high-quality spa cover can fade, crack, and deteriorate prematurely.

With proper spa cover care, your cover can last many years longer.

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How Often Should You Clean a Spa Cover?

Every 6 to 8 weeks.

Regular cleaning removes dirt, oils, and contaminants that clog the vinyl’s surface and cause it to dry out.

What You’ll Need:

• Garden hose
• Gentle liquid dish soap (Ivory, Palmolive, or Dawn)
• Soft sponge
• Clean towel for drying

Cleaning Instructions:

• Rinse the spa cover with a garden hose
• Apply a small amount of gentle soap
• Use a soft sponge to lift dirt
• DO NOT use abrasives or scrub pads
• Rinse thoroughly
• Dry the cover to prevent hard water stains

Tip: Clean your spa cover in the morning while it is cool — never when the vinyl is hot from the sun.

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Protecting Your Spa Cover from UV Damage

Cleaning is only half the equation. UV protection is just as important.

Every other month, apply 303 Aerospace Protectant to protect against slow fading and cracking.

Why 303?

• Reduces UV damage
• Helps prevent fading
• Keeps vinyl flexible
• Acts like sunscreen for your spa cover

Simply spray it on and wipe off any excess with a clean cloth and buff it in with a micro fiber towel.

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Why Maintenance Matters

Vinyl has pores similar to skin. When those pores become filled with dirt and debris, the material can no longer expand and contract properly in heat.

Over time this leads to:

• Cracking
• Fading
• Water absorption
• Premature cover failure

Regular cleaning and UV protection can extend the life of your spa cover significantly — often adding years of use.

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Final Thoughts

A spa cover is an investment. Taking a few minutes every month to clean and protect it can prevent costly replacement down the road.

If you have questions about spa cover care or need a replacement spa cover, contact Spa Covers Etc.

If you own a Sundance® spa, you’ve invested in quality. Protecting that investment starts with a properly fitted replacement spa cover designed to maintain efficiency, safety, and long-term performance.

At Spa Covers Etc., we specialize in custom replacement Sundance spa covers throughout Orange County and most cities in Los Angeles County.

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Why a Properly Fitted Sundance Spa Cover Matters

A worn-out or poorly fitted cover can lead to:

• Heat loss and higher energy bills
• Excess water evaporation
• Increased chemical use
• Debris entering the spa
• Safety concerns for children and pets

A custom-fit replacement cover helps maintain water temperature, reduce operating costs, and protect your spa from unnecessary wear.

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Custom Replacement Covers for Sundance Spas

We do not use generic “one-size-fits-most” covers.

Each replacement Sundance spa cover is built to order based on:

• Exact measurements
• Proper corner radius
• Correct skirt length
• Appropriate foam density

Foam options include:

1.0 lb Density (Standard)
Recommended for warm climates and most portable spas.

1.5 lb Density (Deluxe)
Increased insulation with balanced weight and strength.

2.0 lb Density (Heavy Duty)
Higher insulation value. Recommended for colder climates or in-ground installations.

Super Foam (5″ x 3″)
Thicker core for added structural strength in extreme conditions.

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Professional In-Home Measuring (Orange & LA County)

Sundance spas can vary slightly by model and production year. To ensure accuracy, we offer professional in-home measuring services throughout Orange County and most cities in Los Angeles County.

We also provide:

• Template service for irregular or free-form spas
• Free phone consultations
• Guidance on foam density and insulation options

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Is It Time to Replace Your Sundance Spa Cover?

You may need a replacement if your current cover is:

• Heavy or waterlogged
• Cracked or faded
• Sagging in the center
• No longer sealing properly
• Missing or broken locking straps

Replacing a failing cover can immediately improve heat retention and energy efficiency.

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Get a Quote Today

For spas up to 96″, you can order online.

For oversized or custom Sundance spa covers, call 949-496-2883 for assistance.

Protect your Sundance spa with a custom replacement cover built to fit correctly and last.

Get a quote today. 

Your spa cover is the first line of defense against heat loss, debris, moisture, and safety risks. But not all spa covers are built the same.

Many big-box retailers sell “universal” spa covers. While these may seem convenient, they rarely fit correctly and often fail prematurely.

Here’s why a custom spa cover makes a difference.

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Why Fit Matters

A properly fitted spa cover should:

• Sit flush against the spa shell
• Seal tightly at the edges
• Match the correct corner radius
• Have the correct skirt length

Generic covers often leave small gaps. Those gaps allow:

• Heat to escape
• Water to evaporate
• Debris to enter
• Energy bills to increase

A custom-made spa cover is built to your spa’s exact measurements, ensuring proper insulation and protection.

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Foam Density & Structural Strength

Many generic covers use lower-density foam and minimal reinforcement.

Our custom spa covers allow you to choose:

1.0 lb Density (Standard)
Lightweight and suitable for warm climates.

1.5 lb Density (Deluxe)
Improved insulation with balanced weight and durability.

2.0 lb Density (Heavy Duty)
Higher insulation and added structural strength.

Super Foam (5″ x 3″)
Thicker core for increased strength in extreme conditions.

The right density improves energy efficiency and extends the life of the cover.

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Built for Your Climate

Southern California may not see heavy snow, but covers still face:

• Intense UV exposure
• Rain
• Chemical vapor
• Heat expansion

A well-constructed custom cover with proper taper and reinforced hinge design prevents sagging and premature failure.

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Safety & Compliance

A properly fitted cover with locking straps helps meet ASTM safety standards.

Generic covers that do not seal properly may not provide the same level of protection.

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Long-Term Value

While a generic cover may cost less upfront, a poorly fitted or underbuilt cover often needs replacement sooner.

A custom spa cover:

• Improves heat retention
• Reduces energy costs
• Lasts longer
• Maintains safety
• Protects your spa investment

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Get a Custom Spa Cover Built to Fit

At Spa Covers Etc., every cover is built to order based on accurate measurements and foam selection.

If you need assistance measuring or selecting foam density, call 949-496-2883 for guidance.

Protect your spa with a cover designed specifically for it.