Welcome to our forum.
The materials being used by manufacturers nowadays vs. several years ago are much better in every respect and in my opinion
Actually it adds considerably to the manufacturing costs. However, on an 8' cover this gap can be as much as 96 square inches. That's almost as large as a 10" square. That's a pretty big hole in something that's SUPPOSE to be insulating hot water.*not spell checking, overworked and in a cynical mood today*
I am surpirised that a lot of the regulars did not chime in on this one. Chas, Brewman, Ebbriane, Chris H, Stuart did not chime in. Is this because your tubs do not have bumper seals?