Spa Fitter
Cal Spas Costa X-Series Replacement Cover
The Cal Spas Costa X-Series takes the AIRCAP 1™ Small — a foam-free replacement hot tub cover for square spas 83"–85". The Costa X-Series's cabinet measures 84" x 84", inside the Small'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 | 84" x 84" |
|---|---|
| AIRCAP 1™ size | Small fits 83"–85" |
| 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 Small fits the Costa X-Series
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 Small, which fits cabinets 83"–85", covers the Costa X-Series's 84" x 84" shell with the right overhang. Instead of a rigid foam core wrapped in vinyl, the AIRCAP 1™ uses welded drop-stitch construction (the material of premium inflatable paddleboards): a sealed air chamber that cannot absorb water, so it never becomes the waterlogged, two-person lift that ends most foam covers.
Cabinet dimensions can change between model years. Before ordering, measure your Costa X-Series side to side across the top of the cabinet in both directions — the SureFit™ guide walks through it in two measurements. If your spa measures between two sizes, round up.
Other Cal Spas models we fit
Not a Costa X-Series?
The Spa Fitter matches 363 models across 25 brands to the right AIRCAP 1™ — or measure any square spa with SureFit™.