Hi burnell,
Part of the problem with almost all major brand mattresses is the use of too much cheap low quality polyfoam in the upper layers of the mattress (as you saw). This is an even bigger problem with the pillowtops. The polyfoam will go through an initial softening process in the first 90 days or so and if this makes the mattress too soft … then it’s difficult to fix without surgery and warranties don’t cover foam softening. The good news though is that the innersprings are almost certainly still fine.
I would personally never consider buying latex foam from foam factory (or any of their other names) because I don’t believe they sell talalay and I also don’t believe their ILD ratings. I know they don’t buy foam from either Latex international or Latexco which are the sources of all the Talalay foam in the US. I also don’t believe their ILD ratings for a moment and if you buy the wrong ILD then you can end up with an impossible task trying to figure out exactly what you bought and how to fit it into a suitable layering pattern. The only thing I would consider buying from them is cheap polyfoam and even then only if the situation didn’t demand that I received exactly what I thought I was ordering. More of my thoughts about them are in post #2 here.
I’m not sure if you have the firm or plush pillowtop but if I was going to do mattress surgery on the mattress (which is probably fairly similar to this) … I would look carefully at which foams to keep and which to throw away. I would keep the insulator layer on top of the innerspring and possibly any zoning layer as well. Having a good insulator layer to prevent the foam from sinking into the coils is important. Then on top of this I would probably add 2-3" of latex with possibly up to 2" of good quality polyfoam under this. How much and what firmness would depend on the compromise between you for your individual preferences. Given your higher weight and back sleeping and your wife’s lower weight and side sleeping I would probably lean towards 3" of latex and then add polyfoam under it if this didn’t hit the feel you were looking for. I would tend towards about 24 ILD which would likely be firmer than much of the foam you are replacing.
If you go in this direction … I would be prepared to do some experimenting to get the final result you want.
I would tend to give mattress surgery a try before going in another direction because you can always use any latex you purchase over a 6" latex core if you decide to go in that direction but a latex/innerspring hybrid can make a great mattress.
There are many cost effective mattresses that can be ordered online in many budget ranges … especially from some of the smaller manufacturers who specialize in helping people order mattresses over the phone. If you do decide to go in this direction did you have a budget in mind?
Several members of the site specialize in DIY mattresses or purchases that can be shipped across the country. A brief description of them is in post #21 here. Another option if you decide not to do surgery would be to purchase from a local manufacturer where you could test the mattresses in person. They are usually your best local source of quality and value. If you let me know what city you live in I’d be happy to take a look to see if I know of any close to you.
Lots to think about but mattress surgery would probably be my first choice if you are up for a challenge and a little experimentation.
Phoenix