Pianoman's latex-foam hybrid mattress setup w/PICS!
Jun 4, 2010 7:15 AM
Joined: May 22, 2010
Points: 112
My order of PU foam for my DIY Eastern King latex-foam hybrid mattress from foamdistributing.com arrived yesterday. It included six 82" x 76" x 1" Lux foam skins, plus a 15 lb. bag of shredded memory foam and a 72" x 5" poly round bolster. (I'm going to use the shredded memory foam to try and make my own king size pillows, and I plan to cut the poly round bolster into five 14" lengths to be used for back/lumbar support when sitting).

Everything arrived safely and well-boxed. Here are some pics of the order...

 

The order shipped in four boxes. I opened one box, then remembered to start taking pics...

Contents in boxes... mostly

 

Contents unboxed but still in outer plastic shrink wrap...

Contents still in all plastic

 

Contents with all shrink wrap removed. Note that the contents are packed in an inner, "non-shrinked" plastic bag. They've also expanded somewhat...

Contents with all shrink wrap removed

 

All six layers unpacked and layered on top of one another (bolster and memory foam can be seen underneath piano)...

All six layers together

 

The next six are shots of each layer. These are "crusts" or "skins", so the sides that were against the mold are not pretty. As you can see, the reverse sides are all uniformly beautiful...

Layer #1:

Layer #1

 

Layer #2:

Layer #2

 

Layer #3:

Layer #3

 

Layer #4:

Layer #4

 

Layer #5:

Layer #5

 

Layer #6:

Layer #6

 

I also recorded the dimensions and the weight for each layer and calculated the approximate density of the foam...

Actual Foam Specs

I was pleased to discover that the average density of 2.75 is nearly that of their Lux-HQ foam which is spec'd at 2.8. I was afraid I was going to get something closer to 1.8, which is the density of their Lux-R foam.

Finally, I was surprised at how much give there was to the foam when I began handling it. It seemed much softer than I imagined it would be. Once the six layers were in place on the floor and I lay down on it, however, it seemed firm.

But the proof will be in the pudding. Come on, latex order, hurry up! More pics then...

 

6/12/2010 UPDATELatex Arrived Yesterday... Pics Below!

The three 2" LI Talatech layers arrived from SleepEZ yesterday. Here are some pics...

 

The order shipped in one box (65 lbs.)...

SleepEZ Order — Boxed

 

Unboxed, still in vacuum-packed plastic...

SleepEZ Order — Unboxed

 

Platform Bed Frame (for assembly pics see Wal-Mart Premier Platform Bed Frame (King) — Assembly & Report)...

Wal-Mart Frame Assembled

 

 

Bed frame covered with cardboard from bed frame shipping box...

 

Bed frame and cardboard with 1" Lux-HQ foam skin on top...

 

Bed frame, cardboard and 1" foam skin with Luna 11" King Mattress Encasement open on three sides and with sides folded down over frame. Fourth "attached" side is in front with top folded up under front of bed frame. This mattress protector with "three-sided zipper" (according to Luna website) actually has only two sides zippered. It starts in one corner and goes completely to the opposite corner. I was very frustrated and disappointed to find this out but didn't want to return it and have to wait to obtain a true three-sided zippered cover so I used a utility knife to cut the third side open. Once the layers were in place, I duct-taped the side back together from the inside out.

 

All layers in place — five 1" PU foam skins, two 2" 32 ILD Talatech layers and one 2" 24 ILD Talatech layer...

 

Finished Mattress!!! Sides have been pulled up, "cut" side (top left) duct-taped from inside out, other two sides zipped shut, and the cover is truly a perfect fit. Yesssss!!!

 

So how does it feel? See the rest of this thread for comfort reports and updates.

This message was modified Jun 15, 2010 by pianoman
Re: Pianoman's latex-foam hybrid mattress setup
Reply #1 Jun 4, 2010 1:20 PM
Joined: Mar 14, 2010
Points: 185
You are a motivated man, pianoman. Hope your latex gets there soon so you can get to work!
Re: Pianoman's latex-foam hybrid mattress setup
Reply #2 Jun 4, 2010 2:25 PM
Joined: Oct 15, 2009
Points: 966
What is the ILD of the skins?   They are cheaper because they are the end pieces?
Re: Pianoman's latex-foam hybrid mattress setup
Reply #3 Jun 4, 2010 2:37 PM
Joined: May 22, 2010
Points: 112
cynicaljones wrote:

You are a motivated man, pianoman. Hope your latex gets there soon so you can get to work!

You think so? I think you're motivated, CJ! I've been following your adventures with the different combos of firm/medium/soft layers and hoping and praying that you'll find something really soon that works.

You're also reminding me I need to call Shawn at SleepEZ and check on my latex. He had to get some of my layers from LI because he was out of them, but was expecting them in (to him) yesterday. To the phone I go...

Re: Pianoman's latex-foam hybrid mattress setup
Reply #4 Jun 4, 2010 2:54 PM
Joined: May 22, 2010
Points: 112
sandman wrote:

What is the ILD of the skins?   They are cheaper because they are the end pieces?

ILD of the Lux foam skins is 50. Yes, they're cheaper ($17 vs. $41) because they're the end pieces.

I have no way to compare with the non-skin Lux-HQ foam, but I have noticed a bit of irregularity in the thickness of these layers. One is noticably thicker than 1" and two are noticably thinner. Also, the thickness varies some within each piece itself. Generally the outside fourths toward the sides gradually thin just a bit. So when all six 1" layers are piled on top of each other, there is a small but noticable decline sloping toward the side edges. I don't believe this will negatively affect the function in any way. I would think that this "issue" would be virtually nonexistent if the core was one solid 5" block instead of five 1" blocks (my sixth layer will go between my mattress and my platform... "pretty" side up, btw... LOL). Any slight irregularities in the cut would not be multiplied by five as they are in my situation.

This message was modified Jun 12, 2010 by pianoman
Re: Pianoman's latex-foam hybrid mattress setup
Reply #5 Jun 5, 2010 10:50 PM
Location: L.A. area
Joined: Jan 18, 2008
Points: 1161
Interesting. Nice photo essay. Look forward to hearing how you like it.
Re: Pianoman's latex-foam hybrid mattress setup
Reply #6 Jun 10, 2010 8:38 PM
Joined: May 22, 2010
Points: 112
Latex supposed to arrive from SleepEZ tomorrow! Getting a little excited!
Re: Pianoman's latex-foam hybrid mattress setup
Reply #7 Jun 10, 2010 8:45 PM
Joined: May 22, 2010
Points: 112
pianoman wrote:

Also, the thickness varies some within each piece itself. Generally the outside fourths toward the sides gradually thin just a bit. So when all six 1" layers are piled on top of each other, there is a small but noticable decline sloping toward the side edges. I don't believe this will negatively affect the function in any way. I would think that this "issue" would be virtually nonexistent if the core was one solid 5" block instead of five 1" blocks (my sixth layer will go between my mattress and my platform... "pretty" side up, btw... LOL). Any slight irregularities in the cut would not be muliplied by five as they are in my situation.

I could probably solve any slope issue by cutting half of my pieces in half (so they are TwinXL sizes) and orienting them so that they taper toward the middle of the bed. This would offset the aforementioned downward slope toward the edges.

Re: Pianoman's latex-foam hybrid mattress setup
Reply #8 Jun 12, 2010 10:01 PM
Joined: May 22, 2010
Points: 112
Latex arrived yesterday. Bed frame and mattress are now assembled, sheets are washed and on the bed and my wife just told me she's turning in for the night. I'll give you updates as the days go by.

Also, I just added pics of the frame, latex and mattress assembly in my original post in this thread, so check it out if you're interested. G'nite!

This message was modified Jun 12, 2010 by pianoman
Re: Pianoman's latex-foam hybrid mattress setup
Reply #9 Jun 12, 2010 10:24 PM
Joined: Mar 14, 2010
Points: 185
Ha!! cheeky You win for most motivated! I concede (though I did do one more configuration I hadn't thought of, until Shaun recommended it). I hope it works for you.
Re: Pianoman's latex-foam hybrid mattress setup
Reply #10 Jun 12, 2010 11:36 PM
Joined: May 22, 2010
Points: 112
cynicaljones wrote:

Ha!! cheeky You win for most motivated! I concede (though I did do one more configuration I hadn't thought of, until Shaun recommended it). I hope it works for you.

I hope so, too, 'cause getting back into the mattress to make any changes is going to mean more surgery! (Darn two-sided zipper. Remind me to call or email Luna Monday and see what the deal is with their "3-sided zipper".)

What's your latest configuration?

Re: Pianoman's latex-foam hybrid mattress setup
Reply #11 Jun 13, 2010 12:11 AM
Joined: Mar 14, 2010
Points: 185
Just soft over firm, just the two layers. So far, I've had the best nights' sleep since I've had the bed. Hopefully, I'll be able to determine if I need to exchange my medium layer for a F or XF
Re: Pianoman's latex-foam hybrid mattress setup
Reply #12 Jun 13, 2010 9:45 PM
Joined: Sep 6, 2008
Points: 87
Hey Pianoman ... Great post how is it working for you?  Is it comfortable?  Do you do much Jazz ... ?cool
Re: Pianoman's latex-foam hybrid mattress setup
Reply #13 Jun 13, 2010 9:50 PM
Joined: May 22, 2010
Points: 112
Well I've had only one night on it and my sleep was fitful, but that's 'cause I got a little sunburnt Friday. In fact, I still hurt today! (Gotta love that "farmer's tan"... brown neck and arms. Hey, I only had my shirt off an hour! Course it was midday...)

I'm going to give it a few nights before passing any judgment. I'll plan to update on Wednesday, 6/16.

This message was modified Jun 16, 2010 by pianoman
Re: Pianoman's latex-foam hybrid mattress setup
Reply #14 Jun 13, 2010 10:18 PM
Joined: May 22, 2010
Points: 112
By the way, I don't really do jazz. Some classical, some improv (not jazz, more "pop" or New Age feel). Lately I've been writing some.

Oh, one more thing... I made my pillows today. Here's a couple pics.

 

Stuffing the memory foam in the pillow case...

 

Finished pillows...

Re: Pianoman's latex-foam hybrid mattress setup
Reply #15 Jun 13, 2010 11:06 PM
Ouch
Location: San Jose, CA
Joined: Apr 4, 2010
Points: 143
You know, there are companies sell pillows already made. I've seen them.
Re: Pianoman's latex-foam hybrid mattress setup
Reply #16 Jun 13, 2010 11:58 PM
Joined: May 22, 2010
Points: 112
garypen wrote:

You know, there are companies sell pillows already made. I've seen them.

You're kidding! laugh

Re: Pianoman's latex-foam hybrid mattress setup
Reply #17 Jun 14, 2010 3:13 PM
Joined: May 22, 2010
Points: 112
I used my homemade King pillow last night and may have to remove a bit of the shredded MF. We always put two pillowcases on each pillow to help keep them cleaner. The double case seemed to stiffen the pillow and reduce the luxurious feel of the MF. The pillow fits pretty tight and probably needs to be a little smaller to make it more pliable.

Regarding the Luna mattress encasement, I looked again at their web site and noticed I had missed the part in the description that says "Easy to apply with zippered side and foot fully enclosing the mattress". My mistake. It does zip up on only two sides and it does state that in the description.

So what's up with the part that says "3-Sided Bed Bug Proof Zipper Fully Seals Off the Encasement"? Well, I called Luna (before even needing to be reminded by you, CJ!) this morning and found out that they're referring to the type of zipper here. It's a special zipper that's different from a regular "two-sided" zipper like you would find on a zip-up jacket or coat, for example.

Now I sorta wish I had gone with my original encasement idea, the Zip It Bug - Allergen, Dust Mite Mattress Encasement with Smart Zipper - King Size. It was $25 cheaper than the Luna, and I found out from online chat with PestMall that the Zip It Bug encasement is truly zippered the full length of three sides of the mattress. The two reasons I ended up going with the Luna instead are that you can get it in different heights (9", 11", 13", 16" 20") which would give me a perfect fit for my 11" mattress (and it is a perfect fit!) and it is made in the USA (thought I'd support our fellow Americans). The Zip It would have been a little loose... not a perfect fit. But I would probably trade that for not having to do "mattress surgery" like I did on the Luna, which of course voids Luna's 10-year warranty.

Live and learn!

Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #18 Jun 16, 2010 9:26 PM
Joined: May 22, 2010
Points: 112
Here's my promised Wednesday update. The new mattress has been fine so far. Any position — back, side, stomach — on it is comfortable. I'm mostly a side sleeper, and that has been no problem since I tweaked my pillow a bit to make it just the right height. The wife has said nothing, which is her way of giving approval. You usually only hear from her if there's a problem.

I sometimes get too hot, but we don't keep our home real cool at night. If I sleep with only a sheet on top, I'm okay, but if I forget and leave the blanket on as well I get hot. We're using a 100% polyester mattress pad, so I'm sure that doesn't help. I may ask the wife if we can ditch the mattress pad for a night ot two and just put down another cotton sheet underneath the fitted bottom sheet to see how that works. This'll put us closer to the latex and totally get rid of the dreaded (cue ominous music here...) polyester!

Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #19 Jun 20, 2010 11:54 PM
Ouch
Location: San Jose, CA
Joined: Apr 4, 2010
Points: 143
Pianoman - One thing I've been wondering ever since I first saw those photos: Why buy six of those ratty-looking skins instead of one solid 6" thick piece? Were they that much cheaper than a solid 6x76x80 piece of Lux-R for  $166?
Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #20 Jun 21, 2010 1:35 AM
Joined: May 22, 2010
Points: 112
garypen wrote:

Pianoman - One thing I've been wondering ever since I first saw those photos: Why buy six of those ratty-looking skins instead of one solid 6" thick piece? Were they that much cheaper than a solid 6x76x80 piece of Lux-R for  $166?

Yes, sort of. I was actually substituting the skins in place of the Lux-HQ foam. Since I always planned to use one of the skins to act as a buffer between the mattress and the metal platform frame, we'd have to compare the cost of five skins to the cost of one 5" piece of Lux-HQ foam. At $17/ea x 5, the skins come in at $85. The 5" Lux-HQ would have been $204. That's a savings of $119. I'll take that!

No one will ever see the "ratty-looking skins", they're fully encased, and having them in 1" layers allows me to make small (or larger) changes to the setup of the mattress if I so desire. Plus they're much easier to handle than a 5" x 76" x 80" block of foam weighing in at around 52 lbs.

This message was modified Jun 21, 2010 by pianoman
Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #21 Jun 21, 2010 3:45 AM
Location: L.A. area
Joined: Jan 18, 2008
Points: 1161
I think the 1" layers was a good idea - it will indeed give you a good ability to adjust the feel of the mattress. Maybe not as much as 1" layers towards the top would, but nevertheless..

Look forward to see how this feels after a month or so...

Does that frame make any noise?

Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #22 Jun 21, 2010 12:06 PM
Ouch
Location: San Jose, CA
Joined: Apr 4, 2010
Points: 143
jimsocal wrote:

 

I think the 1" layers was a good idea - it will indeed give you a good ability to adjust the feel of the mattress. Maybe not as much as 1" layers towards the top would, but nevertheless..


If they were standard 1" layers, I might agree. But, the end pieces are recommend as single bottom layers specifically for their hard surface on the crust side. So, I can see using one for the top of the foundation, as he did. But, I would bet a dollar that a 5" piece of foam will support and react to pressure and weight more consistently throughout the mattress, than a ragtag pile of end pieces from different manufacturing runs.

This message was modified Jun 21, 2010 by garypen
Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #23 Jun 21, 2010 12:21 PM
Ouch
Location: San Jose, CA
Joined: Apr 4, 2010
Points: 143
pianoman wrote:

 

 

Yes, sort of. I was actually substituting the skins in place of the Lux-HQ foam. Since I always planned to use one of the skins to act as a buffer between the mattress and the metal platform frame, we'd have to compare the cost of five skins to the cost of one 5" piece of Lux-HQ foam. At $17/ea x 5, the skins come in at $85. The 5" Lux-HQ would have been $204. That's a savings of $119. I'll take that!

No one will ever see the "ratty-looking skins", they're fully encased, and having them in 1" layers allows me to make small (or larger) changes to the setup of the mattress if I so desire. Plus they're much easier to handle than a 5" x 76" x 80" block of foam weighing in at around 52 lbs.


I must have misread your original post. I thought you said you had ordered Lux-R, which the website states is $166 for a 6". (5" is $138) I didn't realize the skins were Lux-HQ. 
Also, the website shows the skin price as $22, which didn't seem like that much of a saving vs the equivalent solid piece. Sounds like you've got an uncle in the foam business!

Personally, I still think it would be worth the extra money for a solid piece, as it seems to me, based on logic and physics, that it would react more uniformly, as I stated in response to Jim. Also, it seems like a lot of work to trim all of those irregularly sized pieces so they make a smooth, even, single, mattress-like edge. 

This message was modified Jun 21, 2010 by garypen
Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #24 Jun 22, 2010 1:39 AM
Joined: May 22, 2010
Points: 112
jimsocal wrote:

I think the 1" layers was a good idea - it will indeed give you a good ability to adjust the feel of the mattress. Maybe not as much as 1" layers towards the top would, but nevertheless..

I figured if the mattress ended up being too firm, this would make it easy to take out 1" or 2" of the base foam from either or both sides and add something softer at the top if necessary. (I wanted to keep the total height 11", since that's the height of my mattress cover.)

Look forward to see how this feels after a month or so...

Wife has no complaints. I feel like I'm tossing and turning quite a bit. We'll see...

Does that frame make any noise?

Dead silent so far. As noted in original post, when assembling I cranked down the twelve wingnuts pretty firmly with an adjustable crescent wrench, so that probably helps. BTW, there were assembly instructions included (not that you need them). My wife found them under something yesterday.

Yesterday I checked underneath the frame while my wife was lying on her side of the bed to see if anything sags down through the gaps in the metal frame. It looked great... no sagging at all. So I'm very pleased with my idea of putting the cardboard from the frame box on top of the frame for support. The cardboard does not even look stressed or compressed where it meets the thin wires.

Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #25 Jun 23, 2010 3:00 AM
Joined: May 22, 2010
Points: 112
garypen wrote:

I must have misread your original post. I thought you said you had ordered Lux-R, which the website states is $166 for a 6". (5" is $138) I didn't realize the skins were Lux-HQ. 
Also, the website shows the skin price as $22, which didn't seem like that much of a saving vs the equivalent solid piece. Sounds like you've got an uncle in the foam business!

Personally, I still think it would be worth the extra money for a solid piece, as it seems to me, based on logic and physics, that it would react more uniformly, as I stated in response to Jim. Also, it seems like a lot of work to trim all of those irregularly sized pieces so they make a smooth, even, single, mattress-like edge. 

The foamdistributing.com website just calls them "Lux Foam". When I originally ordered them, I had forgotten that there is Lux-HQ grade (2.8 density) and Lux-R (1.8 density). When someone pointed that out to me after I ordered, my heart sank a little, as I definitely did not want the lower-grade Lux-R. But when I measured the pieces and calculated the density, they all came in at 2.7 or 2.8, same as the Lux-HQ. Maybe I got lucky.

No uncle in the foam business, but perhaps by buying all those skins I somehow affected the laws of supply and demand! When I ordered my skins on 5/28/10, the HD36 was $15/ea. and the Lux was $17/ea. Now they're $21 and $22 respectively.

It might be worth the extra money for a solid piece (or maybe two, to allow some flexibility). I can't say much about variances in uniformity of reaction, but I figured under six inches of latex, the base foam is simply providing a firm foundation for the more critical medium and soft latex layers.

Regarding trimming, I trimmed my pieces one at a time, but if I could do it over again, I'd stack the six 1" layers and trim them all at once. This would involve just two cuts — the same amount as cutting a solid piece — and would insure a uniform edge. I just didn't think of that... until now.

I went super cheap on the base foam ($85 total for 5") simply to get as much mattress as I could for as little $$$ as possible. By shaving the budget here, I was able to go for 6" of latex instead of just 4". It was worth it to me. I almost went for an all-latex mattress, but that would've been so much more and I wanted to be sure I liked latex before shelling out $1400. So I decided for $85 I couldn't go too wrong.

Someday I may replace the base with a latex core. That'll be awhile, though!

Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #26 Jun 23, 2010 2:03 PM
Ouch
Location: San Jose, CA
Joined: Apr 4, 2010
Points: 143
pianoman wrote:

 

Someday I may replace the base with a latex core. That'll be awhile, though!


That might be nice and all. But, if the PU is working well as the base layer, why change? I could see choosing all-latex for the initial purchase, trying to go all natural avoiding synthetic products for health or environmental reasons, or for comfort of course. But, if the comfort is there, and you've already made the environmental impact by initially purchasing the PU, why swap the base layer? Use the money towards a new keyboard or something. Rock on with your bad self.

Re: Pianoman's latex-foam hybrid mattress setup w/PICS!
Reply #27 Jun 30, 2010 9:44 PM
Joined: May 22, 2010
Points: 112
garypen wrote:

That might be nice and all. But, if the PU is working well as the base layer, why change? I could see choosing all-latex for the initial purchase, trying to go all natural avoiding synthetic products for health or environmental reasons, or for comfort of course. But, if the comfort is there, and you've already made the environmental impact by initially purchasing the PU, why swap the base layer? Use the money towards a new keyboard or something. Rock on with your bad self.

Planning to swap only when the PU foam gives up the ghost... hopefully it'll be a number of years before that happens.

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