Hot tub cover repair

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dogsbody

Well-known member
Nov 10, 2024
101
Calgary AB
(I hope I'm in the right thread...)

8'x8', two big styrofoam blocks that fold in half, then stand up with the help of a cover lifter.
The center seam (where it folds) has blown out starting at one end, and since the PO neglected
it rather than fix it while it was small, it's now extended 3' across and the edges atrophied and
pulled back. So I now have about a 1/2" gap to close.

Someone in another thread (predictably) said "duck tape". I - professionally - hate adhesive tape.
Over time the adhesive goes to Hades - gums up and turns into a gooey mess. Or hardens and
flakes. Or leaves some unidentifiable (and uncleanable) residue. And being outside, exposed to
water and sunlight and temperature extremes (around here, -40C to +30C) assures that it'll become
the worst it can, and the duck and plastic will just fall off and I'll be left with a bigger problem than I
have now.

I've used Tear-Aid on a tent, and it worked well, but is ridiculously expensive and not meant for
repairs this long. Are there any new tapes out there (Gorilla, maybe?) that have the strength and
longevity - as well as low-temperature flexibility - that this fix needs?

Thanks.
Jonathan
 
I see you're in NY, so you probably know something about winter. How cold does it get there? And is the tape on a hinge/folding point or somewhere it's repeatedly flexed in cold temps?

As far as "biting the bullet", that's not on the menu at present. First, we just got our first real snow of the season, about a foot, so we're locked in for winter. And before I do anything (come spring), I'm much more likely to take out the foam block and stitch a patch over it. This whole thing is complicated somewhat by the presence of speakers that stick up above the height of the rest of the tub rim, and which the cover has to accommodate. So I can't just get a plain old flat-bottomed cover, meaning increased hassle (and probably cost) to replace.
 
I have an old Covermate Lifter. They have since changed the way it attaches to the cover, but the brackets on mine are glued to the cover. I had that cover lifter attached to my cover for almost 4 years now. Still as solid as ever. This is glue I believe they used https://www.3m.com/3M/en_US/p/d/v000311416/ Scotch Weld PR40.I know it was a 3M Scotch Weld Super Glue, and it was clear and very thin/low viscosity

You could get a strip of hot tub cover material and glue it across the gap, acting like a hinge. For the material you could try contacting a place that makes boat covers/tops and seeing if they have a scrap they can sell (or give) you. Or post on craigslist or FB marketplace. Ask if anybody is getting rid of an old cover, can you stop by and cut off a strip. Or maybe your local spa dealer has a old cover they swapped out and you can get a strip of fabric there. Of if you are really desperate, just buy two yards of waterproof canvas for under $40 US, make a hinge strip, and have a bunch left over for arts and crafts. https://fabricwholesaledirect.com/p...H53CU6XwEPJ4JT3NIaeKvLSDTCLanKNMaAkAsEALw_wcB
 
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Sure, that all makes sense. The 3M stuff you mention is probably one of about a zillion cyanoacrylates that'll do the job; as for the patch material, I sail cats, so in addition to the sailmakers I deal with the folks who do covers and trampolines, and all kinds of weird fabrics made for very tough outdoor use, and suppliers like Sailrite. So there are lots of options, and a fix like this is mos def raiding-the-scrap-heap territory.
 
dogsbody said:
Sure, that all makes sense. The 3M stuff you mention is probably one of about a zillion cyanoacrylates that'll do the job; as for the patch material, I sail cats, so in addition to the sailmakers I deal with the folks who do covers and trampolines, and all kinds of weird fabrics made for very tough outdoor use, and suppliers like Sailrite. So there are lots of options, and a fix like this is mos def raiding-the-scrap-heap territory.
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Heck, in that case you might even be able to get somebody to hem the piece for you so it looks nice.

I know a guy who used to work in a sail loft, but that was down in Maryland, so not much help, but you have your own source now, so perfect. The guy moved on from making sails anyway, and he manages one of the naval architecture labs at Annapolis now.
 
The foam in the lid can get waterlogged over time, which makes it very heavy - and that's when seams tend to rip. Is the cover heavy? It sounds like it might be a longshot, but look for an insulating foam manufacturer in your area (search for SIPS or EPS) and see if they can make you replacement foam. Bonus points to them if they can also laminate some fiberglass-reinforced plastic to it to minimize the water intrusion.
 
Thanks for the tip. I've always been a little skeptical about this waterlogging business - if the foam is closed-cell, it shouldn't take up any water, right? In any case, no indication (based on perceived weight and compared to nothing) that it's any heavier than it should be. But we'll be keeping an eye on it, and most importantly, keeping it swept off as the snow falls. One benefit we have here is the Chinook, a warm wind from the coast (we're on the eastern slopes of the Rockies) that turns winter into summer, literally overnight, for a few days to a few weeks, sometimes longer. Perhaps I'll take advantage of one of these respites to lay on some tape and see how it holds, just to keep the water out until spring.

(Trivia: My home town of Pincher Creek AB holds the national record for positive temperature slew rate - more than 40C in one hour, from -22C to +19C. Crazy place to live.)
 
phonedave said:
I know a guy who used to work in a sail loft, but that was down in Maryland, so not much help, but you have your own source now, so perfect. The guy moved on from making sails anyway, and he manages one of the naval architecture labs at Annapolis now.
Click to expand...

Don't want to get too far OT, but I've passed through your neighborhood a couple of times over the past few years to fetch boats, first from Long Island, then this past summer from VT. Your buddy might find interesting that they were (are) both SuperCats (now the ARC boats) with an elliptical hull cross-section designed by a Pratt+Whitney engineer about 45 years ago. Just an amazing design, way ahead of its time.
 

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