Spa Fitter
Cal Spas Windsor Replacement Cover
The Cal Spas Windsor takes the AIRCAP 1™ X-Large — a foam-free replacement hot tub cover for square spas 92"–94". The Windsor's cabinet measures 93" x 93", inside the X-Large'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 | 93" x 93" |
|---|---|
| AIRCAP 1™ size | X-Large fits 92"–94" |
| 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 X-Large fits the Windsor
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 X-Large, which fits cabinets 92"–94", covers the Windsor's 93" x 93" shell with the right overhang.
At 93" the Windsor sits mid-band in the X-Large's 92"–94" range, 1" off the bottom and 1" off the top. Within Cal Spas, the Windsor shares that 93" x 93" cabinet with Atlantic Plus, Atlantic X-Series, Avalon Plus and Avalon X-Series — same footprint, same cover. Cal Spas builds the 37 models we fit on 4 footprints, and the Windsor is on the largest of them; the line spans 4 of the six AIRCAP 1 sizes.
Cabinet dimensions can change between model years. Before ordering, measure your Windsor 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.
Every spa in our catalogue that measures 93" x 93" is on one page: hot tubs that take a 93" × 93" cover — the same AIRCAP 1™ X-Large, 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 Cal Spas model we fit
| Model | Cabinet | AIRCAP 1™ |
|---|---|---|
| Hawaiian PZ-620L | 78" x 78" | XX-Small |
| Hawaiian Plus PPZ-634L | 78" x 78" | XX-Small |
| Maui PZ-620B | 78" x 78" | XX-Small |
| Maui Plus PPZ-634B | 78" x 78" | XX-Small |
| Baja X-Series | 84" x 84" | Small |
| Costa X-Series | 84" x 84" | Small |
| Escape Baja | 84" x 84" | Small |
| Escape Costa | 84" x 84" | Small |
| Escape Pacifica | 84" x 84" | Small |
| Escape Tropical | 84" x 84" | Small |
| Pacifica Plus | 84" x 84" | Small |
| Pacifica X-Series | 84" x 84" | Small |
| Platinum Arcata | 84" x 84" | Small |
| Platinum Huntington | 84" x 84" | Small |
| Platinum Laguna | 84" x 84" | Small |
| Platinum Pismo | 84" x 84" | Small |
| Tropical Plus | 84" x 84" | Small |
| Tropical X-Series | 84" x 84" | Small |
| Malibu EC-754DL | 87" x 87" | Medium |
| Atlantic Plus | 93" x 93" | X-Large same cover as the Windsor |
| Atlantic X-Series | 93" x 93" | X-Large same cover as the Windsor |
| Avalon Plus | 93" x 93" | X-Large same cover as the Windsor |
| Avalon X-Series | 93" x 93" | X-Large same cover as the Windsor |
| Bel Air Plus | 93" x 93" | X-Large same cover as the Windsor |
| BelAir X-Series | 93" x 93" | X-Large same cover as the Windsor |
| Cancun X-Series | 93" x 93" | X-Large same cover as the Windsor |
| Escape Atlantic | 93" x 93" | X-Large same cover as the Windsor |
| Escape Avalon | 93" x 93" | X-Large same cover as the Windsor |
| Escape BelAir | 93" x 93" | X-Large same cover as the Windsor |
| Escape Cancun | 93" x 93" | X-Large same cover as the Windsor |
| Escape Malibu | 93" x 93" | X-Large same cover as the Windsor |
| Malibu X-Series | 93" x 93" | X-Large same cover as the Windsor |
| Platinum Avila | 93" x 93" | X-Large same cover as the Windsor |
| Platinum Carmel | 93" x 93" | X-Large same cover as the Windsor |
| Platinum LaJolla | 93" x 93" | X-Large same cover as the Windsor |
| Platinum Ventura | 93" x 93" | X-Large same cover as the Windsor |
| Windsor (this page) | 93" x 93" | X-Large |
Cal Spas Windsor cover: common questions
What size hot tub cover fits the Cal Spas Windsor?
The Cal Spas Windsor takes the AIRCAP 1 X-Large, which fits square hot tubs measuring 92"–94" across. The Windsor's cabinet measures 93" x 93", inside that band. Measure your spa side to side across the top of the cabinet to confirm before ordering.
Will the AIRCAP 1 fit a Cal Spas Windsor?
Yes — the Windsor's 93" x 93" square cabinet falls in the AIRCAP 1 X-Large's 92"–94" 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 Cal Spas Windsor 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 Cal Spas Windsor?
The AIRCAP 1 X-Large 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 Windsor?
The Spa Fitter matches the current models of every major brand to the right AIRCAP 1™ — or measure any square spa with SureFit™.