How to Measure Your Hot Tub Cover for an Exact Fit
Ordering a replacement hot tub cover requires precise measurements. A properly fitted cover seals in heat, lowers monthly energy costs, and protects your spa from Manitoba’s severe winter weather and heavy snow loads.
Whether your current cover is waterlogged, sagging, or damaged, follow these step-by-step instructions to take accurate measurements before ordering your custom replacement cover.
Tools You Will Need
Before heading out to your hot tub, grab the following tools:
- Steel Tape Measure: Avoid flexible fabric sewing tapes, as they stretch and create inaccurate readings.
- Carpenter’s Square (or Straight Edge & Ruler): Essential for finding the exact corner radius on rounded spas.
- Notepad & Pen: Record every measurement immediately rather than relying on memory.
Essential Rules Before You Begin
- Measure the Hot Tub, Not the Old Cover: Over time, old foam covers absorb water, sag, and warp. Always measure the outside lip of the acrylic hot tub shell whenever possible.
- Round Up, Never Down: A cover that is slightly too large will still seal effectively. A cover that is even half an inch too small will not sit flat on the acrylic rim, causing major heat loss.
Step 1: Measure Length and Width
Measure the outside edge of the acrylic rim from side to side.
- Measure the total width across the flat edge of the shell.
- Measure the total length across the perpendicular edge.
- If your spa appears square, measure both dimensions to confirm symmetry.
Note: If your hot tub is built into an exterior deck, measure to the outside edge of the acrylic lip rather than the surrounding deck boards.
Step 2: Determine the Corner Radius
Most square and rectangular hot tubs feature rounded corners. Measuring the corner radius correctly ensures the new cover fits snugly without leaving open gaps at the corners.
The Carpenter’s Square Method:
- Place a carpenter’s square flat against the outside corner of your hot tub.
- Identify the exact point where the curved acrylic shell first makes contact with the straight edge of the square.
- Measure from that contact point to the interior corner of the square. This measurement is your corner radius.
Rule of Thumb: If your measurement falls between standard sizes, round down to the smaller radius. A smaller radius creates a slightly squarer cover corner, ensuring full coverage over the acrylic shell.
Step 3: Measure the Skirt Length
The skirt is the fabric flap extending down from the bottom edge of the cover to protect the acrylic seam from UV exposure and heat loss.
- Measure from the top lip of the acrylic shell down to the bottom of the cabinet seam.
- Standard skirt lengths typically range between 3 and 5 inches.
- If your hot tub sits flush inside a timber deck, select a shorter skirt length so the fabric does not bunch up against the deck floor.
Step 4: Account for Cabinet Obstacles and Special Features
Check the top rim and cabinet of your spa for raised components that could interfere with how the cover rests on the shell.
- Top-Mounted Features: Note the position of raised air control valves, speakers, waterfall features, or pop-up control panels.
- Skirt Adjustments: If an obstacle sits directly on the outer lip, you may need a shorter skirt or a custom cutout to allow the cover to lie completely flat.
Step 5: Measure Safety Straps and Hinge Orientation
Safety tie-down straps anchor your cover during high prairie windstorms and keep your spa secure when not in use.
- Strap Length: Measure from the bottom edge of the skirt down to the plastic cabinet anchor clip. Straps should extend at least 6 to 10 inches past the bottom of the skirt.
- Hinge Direction: Note which way the cover folds open. The central hinge seam runs perpendicular to the fold line. Make sure your fold direction clears nearby walls, steps, or cover lifter hardware.
Step 6: Verify All Measurements
Because custom hot tub covers are manufactured to your exact specifications, take two minutes to double-check your numbers before submitting your order.
- Re-measure the overall length and width.
- Confirm your corner radius calculation using the carpenter’s square.
- Verify that your hinge direction runs parallel to your cover lifter bar.
Premium Canadian-Made Covers by PSP Fabricating Inc.
To ensure long-term durability in Western Canada’s harsh climate, Crown Spas & Pools partners with PSP Fabricating Inc. to supply our replacement covers.
Manufactured in Canada, PSP spa covers are engineered with high-density tapered foam cores, reinforced continuous hinges, and heavy-duty marine-grade vinyl treated for maximum UV and mildew resistance. Each cover features a sealed vapor barrier to prevent water absorption and comes backed by a comprehensive manufacturer warranty.
When you purchase custom PSP replacement spa covers through Crown Spas & Pools, you get a precision-built thermal barrier built to handle Manitoba winters.
Expert Order Support in Winnipeg
If you have a uniquely shaped spa or want a professional to verify your measurements, our team is here to help.
Bring your dimensions or a photograph of your hot tub cabinet to our Century Street showroom. We will help you select the right foam density, vinyl color, and skirt length for your setup. While you’re in the store, bring a water sample for our expert, hands-on water testing to keep your spa running clear all season long.