If your spa matches one of our 8 standard sizes and has a common corner radius, a ready-to-ship cover is almost always the right call — it ships in 5-7 business days, costs $695-$745, and uses the exact same build as our custom line. Go custom only when your spa is an unusual size, has an odd corner radius or skirt, or you want a person to confirm every measurement in writing before anything is cut.
That's the short version. Below we'll help you self-diagnose which line fits your spa, and we'll be honest about it: a custom cover costs more and takes longer, so we only recommend it when it actually buys you a better fit. If a standard cover will seal correctly, that's the one to buy.
What's the difference between ready-to-ship and custom hot tub covers?
The difference is fit method and timing, not quality. Ready-to-ship covers are pre-built in 8 stocked sizes and dispatch from our Ontario warehouse in 5-7 business days. Custom covers are built to your exact length, width, corner radius, and skirt after a real person confirms your specs in writing — about 2-3 weeks from confirmed measurements. Materials, warranty, and construction are identical on both.
Every Imperium cover — standard or custom — is made in Ontario with 30oz marine vinyl, high-density EPS foam, a sealed vapor barrier, double-stitched seams, a 5"-to-3" taper, four locking straps, handles, and a full-perimeter skirt. Both carry our 3-year non-prorated warranty. You are not trading down on build by choosing ready-to-ship; you're choosing it because your spa fits a size we already stock.
How do I know if my spa is a standard size?
Measure the top edge of your spa shell outside-to-outside (lip-to-lip), both length and width. If a measurement falls between two stocked sizes, go to the larger one — a slightly roomier cover still seals, while a too-small one rides up at the corners. If your numbers land on one of our 8 stocked sizes — 82x82, 84x84 (the most common), 89x89, 90x90, 93x93, and a few others — and your corners use a common radius, you're a ready-to-ship buyer. Our sizing guide lists every stocked size with person-count ranges.
Two measurements decide it. First, the footprint: measure the actual shell, not your old cover — old covers warp and shrink, so they read smaller than the spa. Second, the corner radius: set a straight edge (a ruler or hardback book) flush against one corner so it touches both straight sides, then measure the gap at the deepest point. Common radii are 2", 4", 6", 8", and 10", though some spas use odd sizes like 3", 5", or 7". If your radius falls between sizes, round down — a radius rounded up makes the cover too tight to seat over the corners. Corner radius is the number one fit issue we see; a 1" error is enough to stop a cover from sealing. Our step-by-step measuring guide walks through both, plus skirt length and taper.
When is ready-to-ship the right choice?
Ready-to-ship is the right choice when your spa matches a stocked size and a common corner radius, you want it soon, and you'd rather not pay extra for a build you don't need. It's in stock, ships in 5-7 business days, and comes with a 14-day return window if the cover is unused and in original condition — so a standard-size replacement is low-risk and the fastest way back to a sealed spa.
This covers most square and near-square spas from mainstream brands. If you've measured, you're confident in your numbers, and they match a stocked size, there's no fit advantage to going custom for that spa — the standard cover is built to the same dimensions you'd be quoting anyway. Choosing it saves you one to two weeks of waiting and keeps the price at the lower end.
When should I order a custom cover instead?
Order custom when your spa doesn't fit a stocked size, has an unusual corner radius or skirt length, or you simply want your fit confirmed by a real person before production. Vintage spas, swim spas, oval, round, octagonal, and rectangular shells (like 84x91) usually fall here. Custom takes about 2-3 weeks from confirmed specs, but it's the safe path when standard dimensions won't seal correctly.
Custom is also the right call if you're unsure of your measurements. Through our Custom Cover Concierge, you submit your numbers and model, and a real person confirms every spec — dimensions, corner radius, skirt, color — in writing before anything is cut. That confirmation step is the whole point: it removes the guesswork that makes an odd-sized order risky. Because they're made to your exact specs, custom covers are non-returnable except where the cover arrives defective or doesn't match the specs we confirmed — your rights for faulty or incorrect goods still apply. That's exactly why we confirm every measurement in writing first.
Ready-to-ship vs. custom: a side-by-side comparison
Here's how the two lines compare across the things that actually drive the decision — fit, speed, price, returns, and who each one is for. Materials and warranty are the same, so they're not what you're choosing between.
| Ready-to-Ship | Custom | |
|---|---|---|
| Best for | Standard-size spas with a common corner radius | Unusual sizes, odd corner radius/skirt, or a person-confirmed fit |
| Fit | 8 stocked sizes, common corner radii | Built to your exact dimensions and radius |
| Speed | Dispatches in 5-7 business days (in stock) | About 2-3 weeks from confirmed specs |
| Price (CAD) | $695-$745 | Quoted individually by spec |
| Measurement check | You measure and choose your size | A person confirms every spec in writing first |
| Returns | 14-day returns if unused and in original condition | Non-returnable except for defects or a spec error on our part (your rights for faulty/incorrect goods still apply) |
| Build & warranty | 30oz marine vinyl, high-density EPS foam, sealed vapor barrier, double-stitched seams, 5"-3" taper; 3-year non-prorated warranty | Identical build and warranty |
| Made in | Ontario, Canada | Ontario, Canada |
Does a custom cover fit better or last longer than ready-to-ship?
No — a custom cover only fits better when your spa isn't a standard size. If your shell matches a stocked size and radius, the ready-to-ship cover is built to those same dimensions, so the fit and lifespan are the same. Both lines use identical materials and the same 3-year non-prorated warranty. Custom buys you a tailored fit for non-standard spas, not a better cover.
This is why we don't push custom by default. There's no durability upgrade hiding in the custom line — the foam, vinyl, vapor barrier, and stitching are the same on every cover we make. If a standard cover seals your spa, paying more and waiting longer for custom doesn't get you anything extra.
How fast can I get each one, and what does it cost?
Ready-to-ship covers are in stock and ship in 5-7 business days from Ontario at $695-$745 CAD, with free shipping across most of Canada. Custom covers run about 2-3 weeks from the moment your specs are confirmed and are quoted individually based on size and options. So the practical trade-off is roughly one to two extra weeks of wait for a made-to-measure fit when you genuinely need one.
What if I'm still not sure which to choose?
If you've measured and your numbers match a stocked size and common radius, choose ready-to-ship with confidence. If your spa is an odd size, your corner radius doesn't match a standard option, or you're not certain of your measurements, start a custom quote — confirming the fit with a person is exactly what that process is for, and there's no obligation to order.
Still unsure after measuring? Email us at support@imperiumcovers.com with your dimensions and spa model and we'll tell you honestly which line fits — including telling you to buy ready-to-ship if that's the right answer. We'd rather you get the correct cover than the more expensive one.
Related reading
Choosing materials and specs: vinyl vs. DuraTex, what marine-grade vinyl means, and what a Canadian winter cover needs.