Spa Fitter
Bueno Spa Chicago Replacement Cover
The Bueno Spa Chicago takes the AIRCAP 1™ Medium — a foam-free replacement hot tub cover for square spas 86"–88". The Chicago's cabinet measures 85.5" x 85.5", which rounds up to 86" — the bottom of the Medium's range. The cover weighs 35–40 lb for life, costs $1,195, is engineered to comply with ASTM F1346-23, and carries a 3-year limited warranty.
| Spa cabinet | 85.5" x 85.5" |
|---|---|
| AIRCAP 1™ size | Medium fits 86"–88" |
| Cover weight | 35–40 lb — constant for life |
| Price | $1,195, free US shipping |
| Skirt | Ziptech™ modular, three lengths included |
| Safety | Engineered to comply with ASTM F1346-23 |
| Warranty | 3-year limited warranty |
Why the Medium fits the Chicago
The AIRCAP 1™ comes in six sizes covering square spas from 77" to 94". Each size is built to overhang its band slightly — that is how a spa cover is meant to sit — so the Medium, which fits cabinets 86"–88", covers the Chicago's 85.5" x 85.5" shell with the right overhang once that measurement is rounded up to 86", as a cover size always is.
At 85.5" the Chicago sits just under the Medium's 86"–88" range and rounds up into it. A cover has to overhang the shell, never stop short of it, so the rule is always to round up. No other Bueno Spa model in the Spa Fitter has the Chicago's 85.5" x 85.5" cabinet. Bueno Spa builds the 9 models we fit on 6 footprints, and the Chicago is on number 4 of 6 from the smallest; the line spans 3 of the six AIRCAP 1 sizes.
Cabinet dimensions can change between model years. Before ordering, measure your Chicago at its widest point across the top, in both directions, including any acrylic lip that overhangs the cabinet — the SureFit™ guide walks through it in two measurements. If a figure you have found elsewhere is larger than ours, an overhanging lip is the usual reason. If your spa measures between two sizes, round up.
A 85.5" x 85.5" footprint rounds up to 86" × 86", and every spa we list at that measurement is on one page: hot tubs that take an 86" × 86" cover — the same AIRCAP 1™ Medium, at the same price.
How the AIRCAP 1™ is built
Instead of a rigid foam core wrapped in vinyl, the AIRCAP 1™ uses welded drop-stitch construction: a sealed air chamber with no foam to absorb water, so it does not become the waterlogged two-person lift that ends most foam covers. More on how it insulates, how it holds up, and why it is foam-free — or estimate what your current foam cover weighs.
Every Bueno Spa model we fit
| Model | Cabinet | AIRCAP 1™ |
|---|---|---|
| Boston | 79" x 79" | XX-Small |
| Jersey | 79" x 79" | XX-Small |
| Dallas | 84" x 84" | Small |
| New York | 85" x 85" | Small |
| Vista | 85" x 85" | Small |
| Chicago (this page) | 85.5" x 85.5" | Medium |
| Denver | 86" x 86" | Medium |
| Hollywood | 86.5" x 86.5" | Medium |
| Vacation | 86" x 86" | Medium |
Bueno Spa Chicago cover: common questions
What size hot tub cover fits the Bueno Spa Chicago?
The Bueno Spa Chicago takes the AIRCAP 1 Medium, which fits square hot tubs measuring 86"–88" across. The Chicago's cabinet measures 85.5" x 85.5", which rounds up to 86 inches — the bottom of that band. Between two sizes you always round up, because an undersized cover will not seal along the edges. Measure your spa side to side across the top of the cabinet to confirm before ordering.
Will the AIRCAP 1 fit a Bueno Spa Chicago?
Yes — the Chicago's 85.5" x 85.5" square cabinet rounds up to 86 inches, the bottom of the AIRCAP 1 Medium's 86"–88" range, and the Ziptech modular skirt system ships with three skirt lengths so the drop over the cabinet adjusts without a custom order. Cabinet sizes can change between model years, so confirm with two quick measurements.
How much does a replacement cover for the Bueno Spa Chicago cost?
The AIRCAP 1 costs $1,195 in every size, including the pump, three Ziptech skirt lengths, and tie-down straps, with free US shipping and 30-day returns. Unlike a foam cover it has no foam core to waterlog, so it stays at its original 35–40 lb weight for life.
How heavy is a replacement cover for the Bueno Spa Chicago?
The AIRCAP 1 Medium weighs 35–40 lb and keeps that weight permanently — its sealed drop-stitch air core cannot absorb water. A foam cover starts at 40–75 lb and gains weight as the foam saturates.
Not a Chicago?
The Spa Fitter matches the current models of every major brand to the right AIRCAP 1™ — or measure any square spa with SureFit™.