Repairing Cracks on a Hot Tub Cover

What You'll Need
A Piece of Loose Vinyl
Vinyl Cleaner
Fine Grit Sandpaper
2 Paintbrushes
Vinyl Adhesive
Vinyl Paint

Hot tub covers are often found outside, and are therefore exposed to the elements for large portions of time. As a result, it is very easy for the vinyl on these covers to become cracked over time. Before running out and buying a new hot tub cover to replace your cracked one, you should carefully consider attempting to repair the cover yourself. With a little time and patience, you should be able to perform the required repair yourself. Below you will find the steps needed to complete this repair.

Step 1: Cut A Patch for the Vinyl

The first step of this repair will be to create a patch for the vinyl cover. To do this, you will need to purchase a piece of loose vinyl from your local hardware store. These pieces can often be found in the automotive section of your local hardware store. Cut a piece of vinyl so that it will completely cover the cracked surface of the hot tub cover, including about 1-inch all around the crack.

Step 2: Thoroughly Clean Surface of Vinyl

After cutting the patch to the correct size, you will need to clean the surface of the vinyl hot tub cover completely before continuing with your repair. Use a commercial vinyl cleaner to completely clean the vinyl in the area of the repair. Vinyl cleaner can be purchased at your local hardware store.

Step 3: Sand Down Vinyl

Next, you will need to create a surface that will be conducive to holding the pieces of vinyl together to one another. To do this, use a fine grit sandpaper on the area all around the crack. Sand the area down until it is slightly rough and uneven.

Step 4: Apply Vinyl Adhesive

With a paintbrush, apply a thin layer of vinyl adhesive to the area you have just sanded, all around the site of the crack in the vinyl. If you use more than a thin layer, the adhesive will seep our around the edges of the patch. If this does happen, however, simply remove the excess adhesive with a clean cloth.

Step 5: Apply Patch to Vinyl

Once you have evenly spread a think layer of vinyl adhesive to the area surrounding the crack, firmly attach the vinyl patch that you cut in Step 1 to the area. Smooth the area where you applied the patch to ensure that there are no bubbles or uneven spots on the patch. You will want to allow the adhesive to dry for at least 24 hours before continuing on to the next step.

Step 6: Paint Area with Vinyl Paint

Once you have allowed adequate time for the vinyl patch to dry, you will need to paint the patch to match the color of the vinyl on the rest of the cover. Before applying paint to the patch, test the paint you have purchased on a small corner of the cover to make sure that the color matches. Once you are sure it is a match, paint over the patch in even strokes. Allow this to dry and then add a second layer of paint to the patch.