I chased this exact mystery for a couple weeks and it’s way more common than people think. I’d top it off at night, cover on tight, then wake up to the water line sitting a few inches lower with zero puddles anywhere. Made me feel like I was losing my mind.
In my case it wasn’t evaporation at all. Inches overnight is usually too much unless the cover is off and it’s super windy. What tipped me off was doing a simple test, I filled it, marked the water line, then shut everything down overnight. No pumps, no heat. The level barely moved. As soon as the circulation pump started running again the next day, the level dropped. That told me it was pressure-related, not the shell itself. Turned out to be a tiny seep at a plumbing joint that only leaked when the pump was on, and the insulation was soaking it up so nothing ever hit the ground.
If you haven’t already, pop a side panel and feel around the insulation near the pump and jets. Damp foam is a dead giveaway. Also check the drain fitting, light housing, and any waterfalls or air lines. Those love to leak quietly. I also learned that slightly unbalanced water can speed up seal wear, so once I fixed the leak I paid more attention to pH drift and alkalinity so I wasn’t stressing the rubber parts constantly.
For small, annoying leaks that are hard to pinpoint, I did have decent luck using aquadoc leak sealer as a temporary fix before tearing things apart. It won’t save a cracked pipe, but for tiny seepage it can slow or stop the drop enough to confirm what you’re dealing with. If it’s consistently losing inches, though, there’s almost always a mechanical reason hiding somewhere, not just water disappearing into thin air. Anyone else notice their loss only happens when the pump cycles on?