DIY Orthotic Makeover: Refurbish Your Top Covers and Walk in Comfort Again

 

Reclaim Comfort Without Replacing Your Orthotics

If your orthotic insoles are beginning to feel less supportive, don’t rush to replace them entirely. Often, it's the top cover—the cushioned layer that sits directly under your foot—that wears out first. Fortunately, you don’t need to spend hundreds on new custom orthotics when a simple DIY top cover refurbishment can make your old pair feel brand new.

In this in-depth guide, we refurbishing foot orthotics walk you through how to bring your worn-out orthotics back to life with minimal cost, effort, and tools—all while restoring comfort, alignment, and function.

Why Refurbishing Top Covers Is a Smart Move

Orthotic top covers endure constant pressure, moisture, friction, and body heat. Over time, these factors break down the materials, causing:

  • Loss of cushioning

  • Odor retention

  • Increased friction and skin irritation

  • Diminished support and stability

While the structural base of your orthotic may remain intact, worn top covers compromise overall performance. A quick refresh ensures that your foot receives the right amount of shock absorption, pressure distribution, and comfort, all without sacrificing the personalized correction your orthotics provide.

What You’ll Need for a DIY Refurbishment

Before getting started, gather the following materials:

  • Replacement top cover material (such as Poron®, EVA, Spenco®, or memory foam)

  • Adhesive (contact cement or high-strength spray adhesive)

  • Sharp scissors or a utility knife

  • Sandpaper (optional, for removing old adhesive)

  • A clean workspace

  • Optional: anti-odor spray or fabric for a final outer layer

These basic tools and materials are widely available online or at orthopedic supply stores.

Step-by-Step Guide to Refurbishing Orthotic Top Covers

Step 1: Remove the Old Top Cover

Peel away the existing top cover. If it’s stubborn, apply gentle heat with a hairdryer to soften the adhesive. Once removed, clean the surface thoroughly and sand down any remaining glue for a smooth finish.

Step 2: Trace the New Material

Place your orthotic on the new top cover material and carefully trace the shape. Be sure to mark the left and right if they are custom-shaped.

Step 3: Cut and Prepare the New Covers

Using sharp scissors or a utility knife, cut along your traced outline as precisely as possible. A snug fit is essential for maintaining balance and support.

Step 4: Apply Adhesive

Evenly coat both the top of the orthotic and the bottom of the new material with adhesive. Allow the glue to become tacky (per product instructions), then press the pieces together firmly, starting at the heel and working forward to avoid bubbles or misalignment.

Step 5: Let It Cure

Place a heavy object over the refurbished orthotics and let them cure for at least 24 hours. This step is crucial for ensuring long-term durability and a strong bond.

Step 6: Trim and Fine-Tune

Once cured, trim any excess material and test the fit inside your shoe. If needed, make small adjustments to the edges for a seamless fit.

Benefits of a DIY Orthotic Refurbishment

  • Cost Savings: Save $100+ by avoiding full replacements

  • Extended Lifespan: Add years to your orthotics with one afternoon of work

  • Custom Comfort: Choose materials tailored to your activity or foot condition

  • Sustainable Solution: Reduce waste by reusing existing hardware

Tailor Your Refurbishment to Your Needs

Different foot types and activities call for different materials. Consider the following combinations:

  • Athletes or runners: Poron® for superior shock absorption

  • Daily wear: Spenco® for comfort and moisture control

  • Sensitive skin: Suede or leather for soft contact surfaces

  • Heavy foot traffic: EVA foam for resilience and durability

Customize your top cover to your lifestyle and notice the instant improvement in comfort and performance.

Walk in Comfort, Stay in Control

Your feet deserve better than worn-out insoles. With this simple DIY orthotic makeover, you don’t just save money—you take proactive control over your comfort, mobility, and foot health.

The next time your orthotics start to feel rough, remember: you can revive them, refresh them, and walk pain-free again—all with a bit of effort and the right materials.

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