In order to save your hot tub from getting filled with leaves, dirt and other debris, it's always a good idea to keep it covered when not in use. These covers are simple to make but are a little heavy and cumbersome to put on and take off continually. To make it just a little easier there are covers you can make with handles. If you leave your hot tub on, a cover will help keep the heat in and lower your energy cost.
Measure your hot tub opening. Hot tubs can come in many different shapes such as, round, square, rectangle or any other shape. You will need to measure the exact shape of the opening to make a pattern to cut your wood and vinyl.
Draw out your pattern using the measurements on a piece of plywood minus 1/4 of an inch. Cut the pattern out of the plywood and then cut it perfectly in half. Then cut the foam to match the pieces of plywood.
Glue the foam insulation on to the bottom of the wood pieces. Simalfa adhesive is the best to use for this project but you can use any adhesive made for foams, vinyls and wood. Glue one piece of insulation onto each piece of wood.
Cut the vinyl 1 1/2 inches larger than each half. Cut another strip that will go from one edge of the cover to the other and 3 inches wide, this is the center strip. Then cut one strip that will go all the way around the outer edge of each half of the cover plus 2 inches. It may take more than one piece to do this, that's okay. The strip should be 6 inches wide.
Lay the vinyl over and under the wood pieces with the right side out. Overlap the vinyl and glue the two pieces together all the way around the half piece. Repeat for the other half. This seam is going to be covered so it doesn't have to look great, you just want it to be closed up well.
Glue the center strip on top of the cover to hold the two sections together. This is considered the hinge of the cover.
Glue the outer strip around each half and let the extra inch on each side hang to overlap with the piece from the other half.
Screw on two handles to each side of the cover. Screw into the wood using a power screwdriver right through the cover. This will make it easier for you to fold the cover over and pull it off.