>

Welcome to The Mattress Underground FORUM! :cheer:
The first place to start your research is the Mattress Shopping Tutorial
Select the Search Forum tab below to gain access to answers to many mattress related questions.
Select the Ask An Expert tab below to reach out to any of our Expert Members for guidance and advice.

Welcome to The Mattress Underground FORUM! :cheer:
  • Page:
  • 1

TOPIC:

My Mattress Building Experience and Lessons Learned 12 Apr 2021 15:56 #1

Hey everyone,

A few months ago I was in the market for a new mattress, initially I was looking at the Helix Dusk Luxe, but after reading more and more about how a lot of the store bought or bed in a box mattresses can develop sagging and how all the review sites are unreliable, I started to read Mattress Underground and think about building my own. What helped pushed me over the edge and decide to build my own, was I had stayed at an Airbnb in Montana with one of the most comfy mattresses. I contacted them to find out what brand it was and found out they had built it themselves. Hearing that was the final straw I needed to decide to dive in and build my own.

The Airbnb hosts had shared their build with me which was:
Top Layer is 3” Serenity by Tempur-Pedic Memory Foam Mattress Topper from Costco
Middle Layer is 3” Ultimate Dreams Queen 3" Talalay Latex Soft Mattress Topper ILD 19
Bottom Layer is a 3” Pure Green Natural Latex Mattress Topper medium firmness IDL 30

It was very plush and comfortable during our stay, but I felt for long term I wanted something a little bit firmer, aiming for the feel of memory foam but with around a medium firmness.

I started off buying Tempur-Adaptive Comfort 3" Memory Foam Mattress Topper as the top layer since I really wanted a soft memory foam top and this was one of the softest I could find from Tempur Pedic. It is the same material they use in the top layer (Tempur ES) of the TempurPedic ProAdapt Hybrid which I liked when I tested out different mattress feels at a mattress store. From searching online I saw speculation that the Tempur ES is 4.1lb/cuft and <14 ILD.

I then bought a Spindle 3” Dunlop Latex Firm layer (5.6 lb/cuft and ~30 ILD @ 25%) for the bottom layer. I chose latex for its durability. I chose Spindle, because at the time I ordered in September 2020 I believe Spindle was using continuous pour Dunlop which was supposed to feel like a cross between Dunlop and Talalay, however just checking their website it seems they have now switched to using molded Dunlop.

Then after receiving the top and bottom, I put them together. Resting on it felt good and I liked the feel, so in order to keep the same firmness I ordered another Spindle 3” Dunlop Latex in Firm for the middle layer.

For encasement I really didn’t like a lot of the encasements I found online which either seemed not suited to memory foam or didn’t seemed more like just a mattress cover/ticking and not sturdy enough to hold things together. After a lot of searching and even looking at sites like Alibaba to see if I could get an encasement, I came up with a hack of ordering a replacement mattress cover for a memory foam mattress. I Googled “replacement mattress cover” and found a couple that looked nice and were suited to memory foam. One was by Tulo (a cheap mattress by mattress firm) and another by Lull. I decided to order the one from Lull since it looked nicer. The Lull mattress is a 10” mattress and I had three 3” layers, so I ordered a filler 1” Latex at 20 ILD to get the mattress to the right height. I also ordered a Ultimate Mattress Encasement from Mattress Safe as a mattress protector which I chose because it had some fire resistance properties and I couldn’t find a fire sock to put the mattress layers in.

Now is when I finally put everything together. It was a bit firm at first, but I thought it would break in after a month. After a month it still felt firmer than I liked, so I ordered a Spindle 3” Dunlop Latex in Medium (4.6lb/cuft and 19 ILD @ 25%) and swapped out my middle firm layer for the medium layer. It helped a little bit, but still felt firmer than I wanted. I finally took off the Mattress Safe encasement which made a big difference, I think whatever fabric they had didn’t have any elasticity and was killing the feeling of the memory foam.

After those adjustments, I’ve been sleeping on the mattress for a few months now and I am really happy with how it turned out. Here is the final build.

Final Build (Queen Size)
Top: Tempur Adaptive Comfort Memory Foam 3” Topper - $350
Middle #1: SleepOnLatex 1” 20ILD Latex Topper - $110
Middle #2: Spindle 3” Dunlop Latex Layer (Medium) - $370
Bottom: Spindle 3” Dunlop Latex Layer (Firm) - $440
Lull Replacement Mattress Cover - $120
Total: ~$1400

Extraneous Expenses:
Spindle 3” Dunlop Latex Layer (Queen size, Firm) - $440
Mattress Safe Ultimate Mattress Encasement - $150
Extra Costs: ~$600

Lessons:
- Finding a good encasement for memory foam mattresses to hold all the layers was tough. I recommend googling “replacement mattress cover” and in particular I found some from Tulo and Lull that your can order. Tulo has online orders, but Lull required calling in and didn’t have an online order option. I told Lull I had just bought the mattress used from a friend and needed a new cover.
- The mattress protector can have a big effect on the feel. If you have memory foam, make sure to find one that works well with memory foam.
- Like the forum & guides warn, I didn’t save any money doing DIY vs buying a mattress. I spent total ~$2000, although it could have been done for $1400, but when building your own mattress it is likely you won’t get things perfect on the first try, and mattress pieces often can’t be returned once they have been opened.
- Overall I was happy with the outcome. I have a bed dialed in to the exact firmness level I like. I’m confident about the durability of the mattress and that I won’t need to replace it in a couple years. Even if one layer does wear out, I can just replace that layer. Finally, I found it a rewarding project doing all the research and building the mattress.

P.S. I still have the extra Spindle Layer (Queen size, firm) and the Mattress Protector. If anyone is interested in purchasing them at a discount, contact me. I live in Sunnyvale, CA if you want to pick up the latex layer (which I believe is continuous pour Dunlop from before Spindle switched over to molded Dunlop). Just email me, jwegan at gmail dot com

Please Log in or Create an account to join the conversation.

Last edit: by jwegan.

My Mattress Building Experience and Lessons Learned 14 Apr 2021 08:24 #2

Hey jwegan,

Welcome to TMU :) !

A few months ago I was in the market for a new mattress, initially I was looking at the Helix Dusk Luxe, but after reading more and more about how a lot of the store bought or bed in a box mattresses can develop sagging and how all the review sites are unreliable, I started to read Mattress Underground and think about building my own. What helped pushed me over the edge and decide to build my own, was I had stayed at an Airbnb in Montana with one of the most comfy mattresses. I contacted them to find out what brand it was and found out they had built it themselves. Hearing that was the final straw I needed to decide to dive in and build my own.


Congrats on your new DIY mattress project :) ! Thanks for sharing your DIY-inspired story and thorough research details; you've provided an excellent template for other consumers to model their research efforts after. Great job on your detective work and perseverance! To your point, while the outcome may have been a bit more on the expensive side, you will have the added benefit of replacing layers as needed over time as they wear and as your body's comfort/ support needs change. It would be interesting to hear how your DIY performs for you after some months pass, so please feel free to stop back by and keep us updated ;) .

Thanks,
Sensei
Sensei(@ TMU Team)
Researching for a mattress?... Be sure to read The Mattress Shopping Tutorial.
Click here for TMU Discount Codes if purchasing from Our Trusted Members.
For any mattress questions Ask An Expert on our forum

Please Log in or Create an account to join the conversation.

  • Page:
  • 1
Moderators: NikkiTMU
TheMattressUndergounf
TMU
TheMattressUndergounf