Hot tub cover options?

[nola mike]

My cover is finally done. As with everything in my life, buying a proper replacement ($400-500) is worth more that the tub ("free", 1996 model that I installed 10ish years ago). Maybe 5-6 years ago I took out the waterlogged EPS foam and cut some XPS to replace it, which insulates better and doesn't waterlog. The vinyl is now toast, so looking at replacement options. Nobody seems to make a generic vinyl pocket cover, and the shipping on a full cover is prohibitive. So trying to see if i just suck it up and buy a custom vinyl cover that I can stuff with my insulation, buy some vinyl (or other material?) and try to either sew it (i don't have a proper machine, but always looking for excuses to buy tools), bond it somehow (adhesive, mechanical), check with my friendly local upholsterer (conveniently have one that's going to replace the top on the mini next week), other?
@tpenfield thoughts?

 

[flashback]

I'm for checking in with your upholstery guy, maybe he will give you a package deal for both items.

 

[tpenfield]

Google some DIY hot tub cover videos for some ideas. Probably can spend about half of what you are looking at to buy one or have one made.