The FrankenBed
Sep 18, 2007 9:17 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
    I initially called my creation the FrankenBed because it was made from "parts." The word is taking on a new meaning, as in, I am creating a monster.

The basic outline was a latex core, an Intelli-Gel topper from MyComfort, and something in between, possibly 2" of Foamex memory foam.

The first major piece to arrive (not counting the foundation on top of a set of Bed Beams), is the latex core. I'll get the Intelli-Gel topper on Monday or Tuesday.

I think I might already have a problem. I ordered an ILD 40 Talatech blend core, and I don't think it's going to be firm enough. I initially ordered a 44 but then changed my mind and went with a 40. I should have stayed with the 44. The core actually tested out at an average ILD of 37.8, but I'm not claiming the 2 points is what makes it too soft. Even on 3 2.8" layers, I can bottom out by sitting down on it hard. It's sitting on a concrete floor covered with carpet and I can definitely feel the floor. At the very least, I need to replace one of the ILD 38 layers, and possibly both.

I can't bottom out all 4 layers, but that's 11" of latex, and support-wise, it feels pretty soft. Laying on my back, it feels very firm, but it feels like my butt sinks down further than it should. In other words it's almost too soft AND too firm at the same time. Too soft for my butt but too firm for my shoulders.

Y'all can go ahead and laugh at me now for thinking I could save money by building my own mattress. Not happenin'. The best that can be said is that maybe my own mistakes can benefit others. I'm debating on what to do. I can be stubborn and order another core, or I can just admit that I made a bad decision and order a support  mattress from someone that allows comfort exchanges. I have to allow that even the 44 might not be firm enough, so a money back guarantee would be a good idea too, the second time around.

I have some decisions to make.
This message was modified Sep 18, 2007 by haysdb
Re: The FrankenBed
Reply #9 Sep 24, 2007 5:50 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
Get this folks: They sent me the wrong size. They sent me an Eastern King. What I ordered was a California King.

How does this happen? I believe I have alluded to the fact that his company seems to be a bit, "disorganized," and this is further proof. First they lose my order for near on two weeks, then I wait ANOTHER two weeks only to receive the wrong size.

I don't even have the packing material any more. I left it at the freight office. I didn't notice it was the wrong size (it never once crossed my mind) until I got it home and was taking it out of the truck and saw Eastern King on the packing. I went ahead and brought it inside and, yup, sure enough, wrong king.

The guy I placed the order with no longer works for the company.

Well, I have always been a firm believer in "stuff happens," and I don't care what happened or who screwed up, but what are you going to do about it? The new manager of the Arizona store inherits a fine problem. Let's see how they handle it.
This message was modified Sep 25, 2007 by a moderator
Re: The FrankenBed
Reply #10 Sep 24, 2007 10:15 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
I just got off the phone with Devin (sp) from MyComfort. He has promised to ship out a Cal King topper ASAP. When it's delivered the freight company will pick up the other topper. Devin asked what I would like him to throw in for my trouble, so I weaseled a seat cushion out of him. Was thinking about buying one of those anyway. ;-)

I was a bit miffed earlier, but MyComfort is handling the problem professionally and appropriately, and like I said, stuff happens. Meanwhile the E King topper is taking up most of my living room.
This message was modified Sep 25, 2007 by haysdb
Re: The FrankenBed
Reply #11 Sep 25, 2007 2:02 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
I slept on my new "mattress" last night. The Intelli-Gel didn't do anything to make my latex core feel more supportive, no surprise there, so I need at least one layer of 44.

Slightly more surprising is that the Intelli-Gel topper won't quite be the entire comfort layer. So in addition to additional support, I need something more conforming under the topper than the IFD 38 latex. This will either be a softer latex (32? 28?) or memory foam.

The flexible slat foundation should be here tomorrow. Presumably that will effect the feel a little bit.
Re: The FrankenBed
Reply #12 Sep 25, 2007 5:57 PM
Location: Mequon, WI
Joined: Aug 30, 2007
Points: 363
haysdb wrote:
Slightly more surprising is that the Intelli-Gel topper won't quite be the entire comfort layer.

How thick is the gel portion of your topper?

Are you primarily a side, stomach, or back sleeper?

Thanks for sharing your experiences with this product.

Re: The FrankenBed
Reply #13 Sep 26, 2007 12:58 AM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
I am a 100% side sleeper.

The Intelli-Gel in the MyComfort topper is 2.25" thick. It sits on 1" of polyurethane foam. The quilted top adds another 1/2".
This message was modified Sep 30, 2007 by haysdb
Re: The FrankenBed
Reply #14 Sep 26, 2007 1:21 AM
Joined: Sep 3, 2007
Points: 167
haysdb, too bad about your topper. Did you say it was ordered from Arizona? Mesa AZ is where I went to order my bed. I called the other day to check on my order, and the guy said he was the new manager. Mine is supposed to be in town tomorrow - I sure hope my order is correct.
Re: The FrankenBed
Reply #15 Sep 26, 2007 1:32 AM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
When I went to the website to find a dealer, the number I was given happened to be the Arizona location. The topper was actually shipped from a manufacturing or fabrication facility in Salt Lake City Utah.
Re: The FrankenBed
Reply #16 Sep 28, 2007 8:35 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
[These next two posts were originally here, but they belong in this thread so I moved them.]


tossnturn wrote:
So is this a current result of your frankenbed? Any chance of  posting some photos? What changes in your purchases would you make '20/20' ? Is the bed heavy with the comfort layer and the mattress core? What is [so far] sleep temp of that layer? With the slat foundation, what is the overall height? Will it fit a headboard? Are you still adjusting it?  What pillow seems to work best with your bed so far ? Thanks for all the research time you've put in  and posted information..

It will look like a typical mattress when I'm done. Right now it looks like the "prototype" that it is -- Eastern King Intelli-Gel topper sitting on top of naked Cal King latex cores, sitting on top the flexible slat foundation, sitting on the floor of my living room. Once I get a proper mattress cover and the right size Intelli-Gel topper, it will be pretty ordinary looking. This is an image from the Intelli-Gel website:


It is pretty heavy. The flexible slat foundation shipped in three boxes totaling 189 lbs. The Intelli-Gel topper weighs 150 lbs. The latex core weighs ~90 lbs.

The total height of the final product will be 19 to 20 inches:
  • 6" foundation
  • 9" support mattress (5.6" latex core plus another 2" of latex or memory foam, plus a stretch knit cover)
  • 4" Intelli-Gel overlay

I am still working on it, but I'm pretty close. The "zoning" of the flexible slat foundation has my spine in pretty good alignment, but the Intelli-Gel sitting directly on the ILD 38 latex is a skosh too firm, so I'm contemplating 2" of either memory foam or latex as the top layer of the support mattress.

The only pillow I have slept with so far is a Tempur-Pedic body pillow. I sleep on my side and I'm a pillow hugger. I have a RejuveNite (Latex International) shredded latex and down pillow coming Real Soon Now.
This message was modified Sep 30, 2007 by haysdb
Re: The FrankenBed
Reply #17 Sep 28, 2007 8:38 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
[This post was originally in this thread, but it belongs in this thread so I moved it.]

tossnturn wrote:
Thanks for your hard work. Are there 'feet' on the slat foundation? You mentioned to get more of the full 'slat' feeling, a thinner core mattress could be used. Based on your recent discoveries and experience. You would still buy the adjustable slat foundation, mycomfort gel layer, but a thinner core mattress [med or firm?], with a HR foam layer UNDER the gel, but above the core mattress? You seem very close at this point, once it 'fits' a zippered mattress cover will enclose it all. Will you need deep pocket sheets? I think reg is up to 10 inches, deep is up to 15', and very deep up to 18-20', depending on brand.

I did not get any feet with my foundation. I did not request any. I upgraded my bed frame to a set of 3 "Bed Beams" which will support the weight of an elephant. However, since the flexible slat foundation is comprised of three sections bolted together, and because the Bed Beams do not provide the recommended center support running head to foot, and because FloBeds recommends 5 slats, two under each head and foot sections, I may add back the two original cross supports I replaced to bring the total to 5. That seems like massive overkill, but they are just going in the trash otherwise so I might as well use them.

I definitely like the flexible slat foundation, and I'm pretty sure I'm going to like the Intelli-Gel topper once I get the right amount of cush underneath. The support mattress could be anything. MyComfort sells innerspring, air and memory foam support mattresses that are specifically designed to be used under their Intelli-Gel overlays. I'm doing latex because I liked the feel of Intelli-Bed's $4000 latex mattress. You could do all Pulyurethane, with maybe a layer of HR, or even the more conventional 2.2 or 1.8 lb foam, on the very bottom for the support core and then something like 4 lb Energia (ILD 27), or memory foam,  under the overlay. I can't begin to recommend any one of these over another because I haven't tried them all, and you might like something different anyway.

The total thickness of the two "mattress" layers will be ~13". My current sheets will fit, but there is no way my fitted sheets will tuck in along the sides because they don't already and my current mattress is only 12" thick, so I will probably buy a couple of deeper fitted sheets.
This message was modified Sep 30, 2007 by haysdb
Intelli-Gel overlay
Reply #18 Sep 29, 2007 7:00 PM
Foam Nerd
Location: USA
Joined: Aug 30, 2007
Points: 605
This ties in with information in this thread, but is here because it specifically relates to the queer way that I'm using my Intelli-Gel "comfort overlay." And before anyone goes off on me, I am not asserting that my creation is superior to an Intelli-Bed or MyComfort mattress. It's just different, OK?

The thing I was most interested in was what was attached to what inside the ticking.
  • The Intelli-Gel is bonded to a 1" layer of  "support foam". Both sides of this foam have a thin layer of something the company calls "anti-torque material" bonded to the foam.
  • The "sitting edges" are "high density" polyurethane foam. These sitting edges comprise 12" at the head and foot and 8" on each side. The density of this foam is such that you don't feel the transition from the Intelli-Gel to the foam. The sitting edges are bonded to the same 1" layer of support foam, and to each other at the corners.
The Intelli-Gel/support foam/sitting edge layer is not attached to the cover in any way. Unstitch one side of the cover and the innards will slide right out. Anyone familiar with a component or "kit" mattress might see where I'm going with this. There are excellent reasons for keeping the overlay intact, but there is one thing about it that is REALLY bugging me. The bottom of the overlay casing is vinyl. Waterproof and unbreathable plastic, sitting between me and $1000 worth of latex. Folks, this just isn't right. It may very well be my imagination, but although the Intelli-Gel does not sleep hot, when I awoke yesterday morning I felt just a bit "sweaty."  I asked the manager of one of the MyComfort stores if anyone has ever complained of that and he he was emphatic - "No, never."

I bought the Intelli-Gel overlay hoping to incorporate the Intelli-Gel into my mattress, as just another layer of "stuff" zipped inside a cover. My idea was that when you looked at my mattress, you would see just that - a mattress, and not layers of foam with a skinny mattress stacked on top. Having the Intelli-Gel be a separate "mattress" DOES have it's advantages, namely that a King-size topper weighs 150 lbs. You heard me right. Stack that on top of 90 to 135 lbs of latex, and you have a heavy mattress that would NOT be fun to move as a single mattress. The Intelli-Gel could be removed from the zippered cover for transport, but then you have the very real concern of damaging the foam under and around the Intelli-Gel.

But the bottom line is it would easy to slide the Intelli-Gel out of the nice stretch knit topper and lay it right on top of a layer of latex inside a zippered cover. And that's the direction I'm heading.
  • A nice cotton and wool mattress cover from FloBeds or SleepEz costs $600. I'll be darned if I want to cover that up. I want to sleep on it!
  • I would rather have just my desired foam layers and then the Intelli-Gel, without any layers of ticking and vinyl between them.
  • I am trying to keep my total stack height of foundation and mattress to 18". Since the foundation is 6.25", that leaves me with 11.75" for my mattress. Not counting any ticking, I have layers of 2.8", 2.8", 1.9", 3.25" for a total of  10.75". Add a cover and I'm right where I want to be.
What is magic about 18"? I think that is what will look nicest with my bedstead.  And I don't need new sheets. :-)
This message was modified Sep 29, 2007 by haysdb

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