I have purchaced a used spa and the cover is cracked an waterlogged. However the vinyl is in great shape. I was able to remove the old foam. What I was wondering is if I get 2 4x8 sheets of 2in think foam board from like Lowes or Home Depot and glue them together then place a peice of luon (spelling?) on top for strengh, cut to shape, and wrap the whole thing in two layers of 6mil sheeting, if that would work as good as a new cover. As anyone done this and had luck with it? Or will it even work?
Thanks in advance!!

That might work. Not sure about finding the two inch thick foam though. I'm looking for it as well to line the inside of the cabinet I've built and don't see it at either the HD or Lowes here local (Newport News VA). Anybody have any ideas as where to find said foam?
Thanks
jrshippy

Check with some auto upholstery shops. They place they get their foam from will have all manners of this material in a variety of strength and thickness.

I have access to such a place here in the West, but there must be similar facilities all over the country.

A few years ago, I need to get some industrial type foam that HD & Lowe's no longer carried. I went to a warehouse the auto shops use and it was piled to the ceilings with every thing foam, hard, soft, and seemingly applicable for what you're seeking.

Keep in mind that the foam you removed from the cover is probably tapered, thicker at the center. I've never experianced a home improvement store not carry 2" extruded and also expanded polystyrine insulation. Every one around here has it. With that said, choose the more expensive, extruded. The reason being is that it is extremely watertight, and has a higher R-value. Also, if you don't plan on walking on the cover, you can simply glue a piece of "luon" *wink* along the center edge of both pieces, along the seam, for regidity. The expanded is no where as strong, watertight, or has the insulating abilities. Most stock covers are expanded.

On the 2" thick insulating foam board material - maybe I'm grossly overlooking it in HD or Lowes. Charger 1, I've read some of your posts where you use it, even seen it in the background of the pictures of the octagon tub you build sides for, but I'm not seeing it in the store. I believe it is the 2" thick stuff made by Corning? I've asked the stores and they look at me like I have two heads.
Any suggestion on where to find?

Ya you hit the nail on the heat as for the manufacturer.... might want to ask them to order it up (might be special order in your area). The pink stuff is made by Owen's, and Dow makes the same stuff but it's blue.

i was thinking of doing the same thing with my 6 ft round spa my question is it acceptable to remake the cover from scratch. i was thinking of using a thick tarp like cover for the top, a 2" foam board for the center ( which i just saw at menards and home depot) and possibly a plastic mesh for underneath.as my cover has a mesh like material underneath. im stuck if i should use an epoxy to adhere together. would it be acceptable?

a LOT of solvents and cements will dissolve polystyrene insulation. Check out 3M 77 spray adhesive...if I'm not mistaken, it's suitable for this application. As far as the mesh bottom you describe, I know what you are referring to, and basically what it is is a material that is water resistant but much cheaper than vinyl, used to lower the manufacturing cost of the cover. You would be better off using Tyvek house wrap

thanks for the advice ill try the tyvek and attempt to make this cover. its not that big of an investment if it shouldnt work