Removing the foam inserts from a hot tub cover

Sallie from Denver Colorado writes:

Hi Pros!

My grand kids climbed on and cracked the foam in my spa cover. Can the foam be replaced without having to buy another complete cover?

If so, how do I remove the foam from my cover?

Thank you!

Hello Sallie,

We do hear quite often about grandchildren “problems”. It is a good thing they are so cute!

You can replace the foam core inserts in any hot tub cover or spa cover. Broken or cracked foam does void the warranty of any cover that The Pros know about, so you will not have any recourse there. The best option is to buy the strongest foam you can get, typically 2.0# density foam to insure your cover has a long and healthy life.

Spa cover foam core insertion/removal

The easiest way to think of removing or replacing your spa cover’s internal foam cores, it to think of the cover as just a giant pillow case, that is hinged together in the middle.

To gain access to the zippers, fold the cover in half, one side on top of the other. If you stand now facing the fold area, you will have both zippers now directly in front of you. Unzip the side that is on the top, all the way to the end. This will give you access to the foam core inside.

Next, pull the cover back over one side of the foam, then the other. Eventually, you will be able to simply pull the rest of the foam core out. Done!

Reinserting the new foam panel is just the reverse of this process.

Do be careful not to snag the vapor barrier that has the foam sealed inside of it, as that will allow moisture into the foam and water logging will begin.

Happy Tubbing!

Ethel Elliott