Spa Fitter
Clearwater Spas Discovery Replacement Cover
The Clearwater Spas Discovery takes the AIRCAP 1™ Small — a foam-free replacement hot tub cover for square spas 83"–85". The Discovery'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 Discovery
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 Discovery's 84" x 84" shell with the right overhang.
At 84" the Discovery sits mid-band in the Small's 83"–85" range, 1" off the bottom and 1" off the top. Within Clearwater Spas, the Discovery shares that 84" x 84" cabinet with Beacon, Cabo, ES84-Lite and ES84L — same footprint, same cover. Clearwater Spas builds the 29 models we fit on 5 footprints, and the Discovery is on number 2 of 5 from the smallest; the line spans 2 of the six AIRCAP 1 sizes.
Cabinet dimensions can change between model years. Before ordering, measure your Discovery 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 84" x 84" is on one page: hot tubs that take an 84" × 84" cover — the same AIRCAP 1™ Small, 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 Clearwater Spas model we fit
| Model | Cabinet | AIRCAP 1™ |
|---|---|---|
| Beacon | 84" x 84" | Small same cover as the Discovery |
| Cabo | 84" x 84" | Small same cover as the Discovery |
| Discovery (this page) | 84" x 84" | Small |
| ES84-Lite | 84" x 84" | Small same cover as the Discovery |
| ES84L | 84" x 84" | Small same cover as the Discovery |
| ES84L-Lite | 84" x 84" | Small same cover as the Discovery |
| ES84N | 84" x 84" | Small same cover as the Discovery |
| Fairview | 84" x 84" | Small same cover as the Discovery |
| Kauai | 83" x 83" | Small |
| Liberty Lake | 84" x 84" | Small same cover as the Discovery |
| Myrtle Beach | 84" x 84" | Small same cover as the Discovery |
| St. Andrew | 84" x 84" | Small same cover as the Discovery |
| Starlight 7L | 84" x 84" | Small same cover as the Discovery |
| Starlight 7N | 84" x 84" | Small same cover as the Discovery |
| Titanium | 84" x 84" | Small same cover as the Discovery |
| Broadmoor | 93" x 93" | X-Large |
| Caribbean | 94" x 94" | X-Large |
| Concordia | 93" x 93" | X-Large |
| ES93-Lite | 92.5" x 92.5" | X-Large |
| ES93L | 92.5" x 92.5" | X-Large |
| ES93L-Lite | 92.5" x 92.5" | X-Large |
| ES93N | 92.5" x 92.5" | X-Large |
| Grand Bahama | 93" x 93" | X-Large |
| Monaco | 93" x 93" | X-Large |
| Orlando | 93" x 93" | X-Large |
| Pearl Island | 93" x 93" | X-Large |
| Starlight 8L | 93" x 93" | X-Large |
| Starlight 8N | 93" x 93" | X-Large |
| Tradition | 93" x 93" | X-Large |
Clearwater Spas Discovery cover: common questions
What size hot tub cover fits the Clearwater Spas Discovery?
The Clearwater Spas Discovery takes the AIRCAP 1 Small, which fits square hot tubs measuring 83"–85" across. The Discovery's cabinet measures 84" x 84", 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 Clearwater Spas Discovery?
Yes — the Discovery's 84" x 84" square cabinet falls in the AIRCAP 1 Small's 83"–85" 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 Clearwater Spas Discovery 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 Clearwater Spas Discovery?
The AIRCAP 1 Small 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 Discovery?
The Spa Fitter matches the current models of every major brand to the right AIRCAP 1™ — or measure any square spa with SureFit™.