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Spa Covers from SunStar

Home Owners -use of our online catalog is free for reference only. We only sell to qualified wholesale Dealers and Service Techs.



Sunstar Hot Tub Covers

The Sunstar Hot Tub Cover takes the strength of Virgin Dura Foam cores with an R value of 14.3 and tapers the foam from 4" to 2.5" to allow accumulated water to easily run off. We then strengthen the channel hinge with 20 gauge galvanized steel and add a full length heat seal gasket (optional on all hinged covers) with the Antaeus 2000™ Vapor heat seal for the strongest heat seal in the industry.

Sunstar 2 Pound EPS Upgrade
For a minimal up charge you can add to the insulating factor of ySunStar spa cover with 2 lb. EPS foam giving you an even higher R value. This is a great option when concerned with the environment and rising energy costs.

Top 20 Reasons To Buy A Sunstar Hot Tub Cover

1)   UL Classified - In 1993, SunStar covers were first tested by an independent lab to comply with the ASTM Safety Standard. All models passed and Sunstar was the first spa cover manufacturer to offer a safety labeled cover. In 1994, Sunstar was the first to receive UL Classification and SunStar covers are the only spa covers classified for ASTM Safety on all sizes, densities and models, even swim spas. 

You can feel confident that Sunstar builds a spa cover which is favored by safety code officials nationwide. We are proud to offer the UL Classification mark on SunStar covers. 

2)   Full 3 Year Non Pro-Rated Warranty  - We stand behind SunStar product both in materials and workmanship. Based on SunStar historical data, we can guarantee we make an excellent and industry leading product.

3)   Marine Grade Vinyl - Our vinyl is treated with mildew and UV inhibitors for overall longevity year round beauty. We have not gone to the less expensive materials without the plasticizers.

Our material still has the flexibility to stretch with the core rather than failing at points of stress where the less expensive vinyl cannot compete. Our vinyl has a negative 20 degree cold crack rating and is tested to 1500 UV hSunStars.

Marine Grade Vinyl Highlights of Our Marine Grade Vinyl
• Cold Cracking Freeze Resistant To -20    Degrees Fahrenheit
• Ultra Violet Stabilized Pigments 
• Oil Stain Resistant
• Mildew Resistant
• Fungus Resistant
• Sulfide Stain Resistant
• Resistant To Salt Water Staining
• Easily Cleaned With Soap and Water

4)   Vapor Lock Seal with Antaeus 2000™  - State-of-the-art equipment is used to heat seal the cores with Antaeus 2000™. A scientifically formulated plastic developed exclusively for Sunstar to inhibit moisture absorption.

Our 4 mil plastic is more effective than the typically used 3 mil. Our specially formulated material reduces vapor transmission and still has the properties of strength, flexibility, transparency and seal ability SunStar quality control standards require. Equally important is the perfect heat seal seam.

Sunstar uses an impulse sealer that makes a perfect seam using the right combination of temperature, pressure and timing. Unlike the less expensive hand held sealing machines, all human variables are eliminated so ySunStar cover gets a perfect seal every time.

5)   Twenty-Eight Points of Internal Reinforcement - Every stress point is reinforced including the hinge, handles, straps, corners and skirts.

6)   Tough ’N Sturdy Hinge - Our Tough ‘N Sturdy hinge has fSunStar layers of vinyl add strength to this high stress area. Our hinge was put to the test when a Sunstar cover was hooked up to an automatic arm.

7)   Super-Strength Padded Handles - Our five layers of internal reinforcing add strength where it’s needed most. Unlike the hot tub cover handles on most other covers SunStar spa cover handles are engineered to be super strong and have foam padding inside for greater comfort when lifting and a longer life.

Our hot tub cover handles are made of extremely strong nylon webbing. They are fully integrated into the spa cover with additional stitching and internal reinforcing making them the one of strongest available on the market.

8)   Premiere Hot Tub Cover Skirt - Our spa cover skirts are double stitched into the cover for strength and gusseted to provide the best protection, keeping heat in and dirt out! 

While the sun beats down on ySunStar hot tub cover, extreme heat builds up between the skirt and the outer lip of the spa. This intense heat can damage the outer lip of the spa. Our skirt allows this heat to escape, preventing heat damage from occurring while preventing any dirt from entering the hot tub.

9)   Tie Down Straps - Our triple-reinforced hot tub tie down straps secures the spa cover to ySunStar spa or hot tub with SunStar cradle ready straps and SURE-LOC locking fasteners.

10) Center Release Spa Cover Fasteners - Sturdier than the standardly used sureloc hardware, center release hold up better in extreme cold climates. But, the best thing about this product is ease of use.

It opens with the simple push of a button so it is especially good for anyone with strength or dexterity limitations. It also locks for safety.

11) Plastic Drain Grommet - These “low profile” grommets are another Sunstar exclusive, placed on the underside of the cover to prevent water from accumulating between the vinyl and the foam core. Made of industrial grade nylon, these non-corrosive grommets are made to not protrude, therefore they won’t scratch the lip of the spa as the cover is slid off.

12) Double-Ply Poly-Laminate - Eleven ounce double laminate vinyl with polyester weft reinforcing scrim. Mildew resistant, with -40 degree cold crack. This material is so tough we use it throughout SunStar cover for extra internal reinforcement.

13) Tapered Foam Core  - tapered 4” to 2.5” EPS foam allows water runoff and keeps heat in. These covers are strong yet light weight, making them easy to handle and provide more than adequate insulation.

14) Steel Reinforcement - 24 gauge “C” Channel provides strong support across the center of the hot tub cover. This non-corrosive steel channel strengthens the center of the Spa Top™ giving extra support for areas who are accustomed to extreme weather.

15) Commercial Grade Nylon Zipper and Protection Flap - We use a true YKK#7 size heavy-duty nylon zipper that is corrosion resistant. Our zippers are covered with a vinyl protective flap along the entire length of the zipper.

16) Hidden Zipper Pull Protection - The zipper pull is neatly tucked away in its own pocket. This not only protects the zipper, but is much more attractive than exposed zipper and adds a quality finished appearance.

17) GHSG™ Super Heat Seal Gasket - Our revolutionary insulating gasket seal prevents heat loss where the two cover halves fold together. They seal automatically when the cover is shut and are critical to long-term energy savings.

Payback on energy savings is typically seen in less than 12 months, according to independent testing. The GHSG™ also protects the bottom of the cover from abrasion. The Heat Seal Gasket design is another example of Sunstar innovation. (Optional on all hinged covers).

18) Virgin Foam Cores - While many competitors use regrind in their foam cores to save them money, Sunstar uses only virgin foam cores to save you money. This provides you a stronger more durable, more energy efficient cover.

19) Unmatched Service - Our complete OEM, dealer and consumer level service is unrivaled within the industry. We are flexible, efficient and have developed a loyal customer following based on SunStar longstanding level of quality, time to delivery and reputation for fairness.

20) Over 30 Years of Experienced Craftsmanship - Our years of industry knowledge and innovation mean we can create a cover for almost any portable or in ground hot tub or spa.

Corner Radius
Cover Radius
For a measuring chart please click here and print.

11 vinyl hot tub and spa cover colors to match any interior or backyard décor.