Spa Fitter
PDC Spas Malibu Replacement Cover
The PDC Spas Malibu takes the AIRCAP 1™ X-Small — a foam-free replacement hot tub cover for square spas 80"–82". The Malibu's cabinet measures 82" x 82", 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 | 82" x 82" |
|---|---|
| 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 Malibu
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 Malibu's 82" x 82" 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 Malibu 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.
Every spa in our catalogue that measures 82" x 82" is on one page: hot tubs that take an 82" × 82" cover — the same AIRCAP 1™ X-Small, at the same price.
Other PDC Spas models we fit
Not a Malibu?
The Spa Fitter matches 496 models across 40 brands to the right AIRCAP 1™ — or measure any square spa with SureFit™.