Spa Fitter
Hot Spring Spas Bolt Replacement Cover
The Hot Spring Spas Bolt takes the AIRCAP 1™ X-Small — a foam-free replacement hot tub cover for square spas 80"–82". The Bolt's cabinet measures 80" x 80", inside the X-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 | 80" x 80" |
|---|---|
| AIRCAP 1™ size | X-Small fits 80"–82" |
| 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-Small fits the Bolt
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-Small, which fits cabinets 80"–82", covers the Bolt's 80" x 80" shell with the right overhang.
At 80" the Bolt sits at the bottom of the X-Small's 80"–82" range, so there is room to spare: the same cover fits anything up to 82". Within Hot Spring Spas, the Bolt shares that 80" x 80" cabinet with Beam — same footprint, same cover. Hot Spring Spas builds the 15 models we fit on 6 footprints, and the Bolt is on number 2 of 6 from the smallest; the line spans 5 of the six AIRCAP 1 sizes.
Cabinet dimensions can change between model years. Before ordering, measure your Bolt 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 80" x 80" is on one page: hot tubs that take an 80" × 80" cover — the same AIRCAP 1™ X-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 Hot Spring Spas model we fit
| Model | Cabinet | AIRCAP 1™ |
|---|---|---|
| Excursion | 78" x 78" | XX-Small |
| Monterey | 78" x 78" | XX-Small |
| Beam | 80" x 80" | X-Small same cover as the Bolt |
| Bolt (this page) | 80" x 80" | X-Small |
| Pace | 82" x 82" | X-Small |
| Flair | 84" x 84" | Small |
| Flash | 84" x 84" | Small |
| Relay | 84" x 84" | Small |
| Rhythm | 84" x 84" | Small |
| Aria | 87" x 87" | Medium |
| Aria NXT | 87" x 87" | Medium |
| Vanguard | 87" x 87" | Medium |
| Vanguard NXT | 87" x 87" | Medium |
| Pulse | 89" x 89" | Large |
| Tempo | 89" x 89" | Large |
Hot Spring Spas Bolt cover: common questions
What size hot tub cover fits the Hot Spring Spas Bolt?
The Hot Spring Spas Bolt takes the AIRCAP 1 X-Small, which fits square hot tubs measuring 80"–82" across. The Bolt's cabinet measures 80" x 80", 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 Hot Spring Spas Bolt?
Yes — the Bolt's 80" x 80" square cabinet falls in the AIRCAP 1 X-Small's 80"–82" 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 Hot Spring Spas Bolt 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 Hot Spring Spas Bolt?
The AIRCAP 1 X-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 Bolt?
The Spa Fitter matches the current models of every major brand to the right AIRCAP 1™ — or measure any square spa with SureFit™.