DIY Mattress

[phoenix]

Hi justinjonesteach,

I have a 4 lb. 3 in. Memory foam topper. it is comfortable for us on a blow up mattress and on an old one sided mattress turned upside down. I imagine it would even be okay for us if we put it on the carpeted floor (maybe not).

Yes, probably not so comfortable on the floor! The 3 lb density is lower than I recommend for a memory foam topper (4 lb) so realize that in a component system it may have a shorter comfort life and may require replacement sooner, but since you’ve already purchased the topper I would not replace it until it becomes uncomfortable for you. If you do end up replacing it in the future, you may wish to consider a memory foam topper that is 4 lb or above in density.

I want to turn it into a mattress by buying a piece of base foam to put under it. I am looking at foamorder.com for a 7 in. piece of polyfoam. Duraflex D30 and D40 both look good because they are between 4 and 5 hundred. They are both 2.5 lbs. D30 says firm with an ild of 30 and D40 says very firm with an ild of 40. I think either would probably be fine for comfort, but would they both also work for edge support? Would they both be considered HR polyfoam because they are above 2.4?

Both of the DuraFlex polyfoam cores you listed are 2.5 lb density, but the compression modulus isn’t listed (needs to be above 2.4, plus density above 2.5 lb to be technically considered high resiliency polyfoam). The EverFlex is listed as high resiliency on the foamorder web site, but not the DuraFlex. You’d want to phone them to confirm before placing an order. A popular ILD for polyfoam cores for many of the simplified choice mattresses is in the mid-30 range, so you’d probably be better off using the D40 versus the D30 in most cases, especially using 4" of plush memory foam on top of the support polyfoam core. But this is a general statement and your individual preferences of course are most important, and I would phone foamorder and explain to them your proposed configuration and ask their advice as well.

Regarding edge support, most polyfoam core mattresses don’t need or use a specific edge reinforcement system, as thicker polyfoam cores of higher ILD and density can provide reinforcement to the edge that is similar, or even superior, to many polyfoam edge systems used in similar mattresses. There is more detailed information about edge reinforcement systems in post #2 here.

Also, where could I find a 10 in. Mattress case for the custom mattress?

Besides the site you are considering for your polyfoam core, you can also take a look at the listing for mattress covers in the component thread here. Many offer covers in that thickness.

Phoenix