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Building my own latex mattress... 29 Oct 2015 14:34 #1

I don't think that I'll be happy until I have exactly what I want with the best materials. Through extensive research, I've found that I could build my own all latex 12" mattress for a good amount less than what it would cost if I bought a complete and already made one. I am 6'0", 180 pounds, and always a side-sleeper. I like a plush or pillowtop type of mattress.

Here's what I was thinking, looking for some constructive criticism. I chose to incorporate dunlop into the core as I've read that it is firmer which makes for a better base.

3" 100% natural talalay (19 ILD)
3" 100% natural talalay (30 ILD)
6" Dunlop blended core (need help with ILD) Maybe 36?

I was looking to buy the 2 100% natural 3" layers of talalay from SleepEz as I know they are a very reputable source. However I am unsure of where to buy the 6" dunlop core from. I see Mattress247 on eBay, FoamByMail/FoamFactory, and SleepOnLatex. All three of these companies sell a 6" blended dunlop core for around the same price. Are there any other companies that sell the 6" core and are these three companies reputable?

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Last edit: by B Feelgood.

Building my own latex mattress... 29 Oct 2015 14:52 #2

Hi B Feelgood,

I don't think that I'll be happy until I have exactly what I want with the best materials. Through extensive research, I've found that I could build my own all latex 12" mattress for a good amount less than what it would cost if I bought a complete and already made one. I am 6'0", 180 pounds, and always a side-sleeper. I like a plush or pillowtop type of mattress.


If you are attracted to the idea of designing and building your own DIY mattress out of separate components and a separate cover then the first place I would start is by reading option 3 in post #15 here and the posts it links to (and option #1 and #2 as well) so that you have more realistic expectations and that you are comfortable with the learning curve, uncertainty, trial and error, or in some cases the higher costs that may be involved in the DIY process. While it can certainly be a rewarding project ... the best approach to a DIY mattress is a "spirit of adventure" where what you learn and the satisfaction that comes from the process itself is more important than any cost savings you may realize (which may or may not happen).

If you decide to take on the challenge then I would either use the specs (if they are available) of a mattress that you have tested and confirmed is a good match for you in terms of PPP (Posture and alignment, Pressure relief, and Personal preferences) as a reference point or blueprint and try and "match" every layer and component in your reference mattress (including any springs, any foam layers, and the cover) as closely as possible or use a "bottom up" approach (see post #2 here ).

There is also more about primary or "deep" support and secondary or "surface" support and their relationship to firmness and pressure relief and the "roles" of different layers in a mattress in post #2 here and in post #4 here that may also be helpful in clarifying the difference between "support" and "pressure relief" and "feel" that may be useful as well.

I was looking to buy the 2 100% natural 3" layers of talalay from SleepEz as I know they are a very reputable source. However I am unsure of where to buy the 6" dunlop core from. I see Mattress247 on eBay, FoamByMail/FoamFactory, and SleepOnLatex. All three of these companies sell a 6" blended dunlop core for around the same price. Are there any other companies that sell the 6" core and are these three companies reputable?



The better online options I'm aware of for individual layers and components for building a DIY mattress are listed in the topper and component list in post #4 here .

If you are considering ordering from Foambymail (AKA FBM or Foam Factory and other names as well) then I would read this post and this post and this topic (about their polyfoam and sources) and this post (presumably from a past employee) before buying anything or considering them as a reliable supplier.

Other than FBM ... I would consider all of the suppliers you listed to be knowledgeable and reliable and they along with others are all included in the suppliers list I linked.

Phoenix
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Last edit: by Administrator TMU. Reason: Updating link to https: status

Building my own latex mattress... 29 Oct 2015 16:27 #3

Thanks for the info my friend :)

Unfortunately, I'm not in close proximity to any all latex manufacturers. Therefore, I'm willing to do a little experimentation and like the idea of doing it myself.

As I mentioned in my previous post, the only latex bed that I've tried is the Kiss mattress. I absolutely loved the top 1.5" layer 19 ILD of talalay latex but wasn't thrilled that it was such a thin layer and didn't like the 1.5" layer of memory foam underneath of it.

I feel pretty comfortable with these two layers. Does this look like a good start? I think that 6" of 19 ILD would be too soft here, correct?
3" 100% natural talalay (19 ILD)
3" 100% natural talalay (30 ILD)

However, I'm unsure of which firmness to order for the bottom dunlop 6" layer.

Can you offer any advice?

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Last edit: by B Feelgood.

Building my own latex mattress... 29 Oct 2015 16:43 #4

Hi B Feelgood,

I feel pretty comfortable with these two layers. Does this look like a good start? I think that 6" of 19 ILD would be too soft here, correct?
3" 100% natural talalay (19 ILD)
3" 100% natural talalay (30 ILD)

However, I'm unsure of which firmness to order for the bottom dunlop 6" layer.


If you aren't using a specific all latex mattress that you have tested and confirmed is a good "match" for you as a reference point then I would take a "bottom up" approach rather than a "top down" approach and decide on your base layer first (or in a three layer mattress the bottom two layers ... making sure that if anything it would be a little on the "too firm" side) and then choose the thickness and firmness of the layer or layers on top of it according to your sleeping experience on your previous choices ( post #2 here and the topper guidelines it links to may also be helpful).

Once you have finalized the thickness and firmness of your layering then you can choose the type of cover you prefer in a suitable thickness.

I would certainly agree that 6" of 19 ILD Talalay would be too thick/soft for most people.

Phoenix
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Last edit: by Phoenix.

Building my own latex mattress... 30 Oct 2015 18:39 #5

I have a question in regard to king sized layers of talalay and dunlop.

Are there any manufactures that offer either a 3" or 6" slab of talalay or dunlop that is one continuous king sized piece? Through my research, it seems as if they are either glued together in the middle or a manufacturer will sell you 2 separate twin-XL sized pieces unglued to make 1 king sized piece.

I also read something saying that all latex molds are only twin-XL in sized, however I have no idea if that's true or not.

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Building my own latex mattress... 30 Oct 2015 18:54 #6

Hi B Feelgood,

Are there any manufactures that offer either a 3" or 6" slab of talalay or dunlop that is one continuous king sized piece? Through my research, it seems as if they are either glued together in the middle or a manufacturer will sell you 2 separate twin-XL sized pieces unglued to make 1 king sized piece.


King size Dunlop 3" or 6" cores without any glue seams are certainly available (although you couldn't ship a single 6" king size Dunlop core through courier because it would be too heavy and it would need to be shipped with a common carrier which is more costly) but the largest continuous piece without glue seams that is available in Talalay is queen size (see post #2 here ).

Phoenix
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Last edit: by Administrator TMU. Reason: Updating link to https: status

Building my own latex mattress... 30 Oct 2015 19:14 #7

Evening Phoenix.

Please correct me if I'm wrong. It sounds like no matter where I order a complete bed made of 100% natural talalay or separate pieces to make my own bed, there will be a ton of separate pieces.

EX: 12" total height
3" top layer is actually 2 twinXL pieces either glued or unglued (manufactures choice)
3" middle layer is actually 2 twinXL pieces either glued or unglued (manufactures choice)
6" bottom/core layer is actually 2 twinXL pieces either glued or unglued (manufactures choice)

Therefore I would actually have 6 pieces instead of three solid pieces.

Would the 6" bottom layer be two 3" pieces glued together to make 6" in height or is there an actual 6" continuous solid one piece?

Edit: I was just watching this video www.youtube.com/watch?v=1J8oSJHT3Eg
I'm pretty sure I talked with this company at some point in time and they told me that they do not sell any king sized talalay pieces in either 3" or 6" that come in one piece. Everything sold in that size in 100% talalay come in two twinXL unglued pieces. However, in this video they clearly show a solid 1 continuous piece talalay topper being put on at the end?

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Last edit: by B Feelgood.

Building my own latex mattress... 30 Oct 2015 19:25 #8

Hi B Feelgood,

Please correct me if I'm wrong. It sounds like no matter where I order a complete bed made of 100% natural talalay or separate pieces to make my own bed, there will be a ton of separate pieces.


Yes ... there would be more than one layer in most latex mattress (outside of some mattresses that only contain a single latex layer ... typically 6" thick).

EX: 12" total height
3" top layer is actually 2 twinXL pieces either glued or unglued (manufactures choice)
3" middle layer is actually 2 twinXL pieces either glued or unglued (manufactures choice)
6" bottom/core layer is actually 2 twinXL pieces either glued or unglued (manufactures choice)


Some manufacturers will give you the choice of whether to order glued or unglued layers (you can also glue split layers together yourself and you can also cut solid layers yourself as well).

Would the 6" bottom layer be two 3" pieces glued together to make 6" in height or is there an actual 6" continuous solid one piece?


Most (but not all) Talalay and Dunlop latex molds are about 6" in height so the original core that thinner layers are generally slit from would be 6". Whether the bottom 6" of a mattress was a single 6" core or a combination of thinner layers glued together (such as two 3" layers) would depend on the specific mattress but it's very common to see solid 6" cores that aren't two thinner pieces glued together to make up the 6".

Phoenix
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Last edit: by Phoenix.

Building my own latex mattress... 30 Oct 2015 20:17 #9

Thank you for the insight.

Do you have any opinion of Mountain Top Foam? www.mountaintopfoam.com/
Speaking in terms of the quality of materials used and also consistency of finished product?

Are Radium Foam and Latex International manufactures of foam or do they supply raw materials to small USA based mattress companies to produce their own foam in respective factories?

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Building my own latex mattress... 30 Oct 2015 20:32 #10

Hi B Feelgood,

Do you have any opinion of Mountain Top Foam? www.mountaintopfoam.com/
Speaking in terms of the quality of materials used and also consistency of finished product?


Mountaintop Foam makes a range of continuous pour Dunlop latex cores that vary from 100% synthetic to 100% natural and are made with 7 zones in each core. They are all high quality and durable materials regardless of the blend. They also come in softer versions than are typical for most Dunlop manufacturers (comparable to the softest Talalay ILD's).

There is more about the different types and blends of latex in post #6 here but the choice between different types and blends of latex is generally a preference and budget choice rather than a "better/worse" choice. There is also more about how Dunlop compares to Talalay in general terms in post #7 here . The MTF continuous pour Dunlop is somewhat in between the two but would be closer to the feel of Dunlop (continuous pour is a version of the Dunlop process).

Are Radium Foam and Latex International manufactures of foam or do they supply raw materials to small USA based mattress companies to produce their own foam in respective factories?


Radium and Talalay Global (formerly Latex International) both manufacture the Talalay latex that is used by mattress manufacturers ... they don't supply either the raw materials or equipment that other companies would need to manufacture latex. They are the only two manufacturers of Talalay latex in the western world.

Phoenix
Researching for a mattress?... Be sure to read The Mattress Shopping Tutorial.
Click here for TMU Discount Codes if purchasing from Our Trusted Members.
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Last edit: by Administrator TMU. Reason: Updating link to https: status
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