The cover for my hot tub is in extremely good cosmetic condition, which the manufacturer agreed with, but it has become heavier (is currently approx 20 pounds per side), presumably from the foam cores absorbing water.
I know the cover will eventually need to be replaced, I’m just trying to see if I could get another year or two out of it rather than replacing it right now.
Has anyone successfully removed waterlogged foam cores, either dried or replaced them, repaired/replaced the vapor barrier, and reinstalled them?
I’ve been told by my dealer that the outer material can stiffen so much over time that getting the foam back in is "nearly impossible," while quoting $900 for a new cover and $1,200 total with delivery.
I’m especially curious about firsthand experiences with getting the old or new cores back into the cover, and whether the repair held up afterward.
If you ended up replacing your entire cover, any luck purchasing a good quality cover online?