Replacing foam in the cushions

hero4theday · Sep 12, 2011

That's exactly what Im planning on doing. I think I saw a 6" memory foam at walmart. Kmart had a king size memory foam as well. Not sure of the measurements. Im not worried about it being cut to the shape of the aft berth just that its comfortable. I figure a cooler would fit nicely between the mattress the companion way ladder and the seat while under way.

Barnacle Bill · Sep 12, 2011

Usually every community of any size will have a place that sells foam to the public as well as wholesale. We have one in my area called A-1 foam and a place like that will have foam of all thicknesses and hardness. You can get a piece the thickness you require and then cut it yourself. The perfect tool to cut foam is an electric knife like what you use for cutting your Thanksgiving turkey. Or a serrated bread knife will work too. You can use your old foam as a pattern and mark the new foam sheet with a magic marker pen. But, when you cut the foam, you want to cut it 1/2 larger all around for a perfect fit. Foam comes in different densities. You don't want something real hard as that will be uncomfortable and something too soft will compress so that you will feel the wood beneath. Something in between so it is easy on your back.

Sumner · Sep 12, 2011

We've gotten foam from the foam factory's wholesale site....

http://www.foamdistributing.com/products/lux-hq.html

We really like the 3 inch Lux High Quality. We have it in the V-berth on the Mac and are going to use it for the v-berth in the Endeavour and just ordered a 3 inch by 82 X 86 for $122 for our bed at home and are using it now. We like it, but it is also the most firm they have. Since it is thinner than what was in the Endeavour we will have more headroom and that might help also in the Mac's aft berth along with the v-berth.

It has a very long life span and is better than any foam I've seen in stores, but is not a memory foam. We cut it like butter with a cheap elect. knife. It is cheaper to just get the full sheet and cut it to size even for smaller cushions. We used it for the....

http://purplesagetradingpost.com/sumner/macgregor-canvas/canvas-20.html

..... cabin cushions also.

Free freight and no tax.

We ordered cut pieces and the 'dry fast' for the cockpit....

http://purplesagetradingpost.com/sumner/macgregor2/outside-31-a.html

...from their other site....

http://www.foambymail.com/LR_2.html

where they will cut to size,

Sum

Our Endeavour 37

Our Trips to Utah, Idaho, Canada, Florida

Our MacGregor S Pages

Mac-Venture Links

voltzwgn · Sep 12, 2011

You might want to ensure what is get is closed cell so it won't soak up water like the open cell will.

Pest UK · Sep 12, 2011

There's memory foam and there's 'Tempur memory foam' which is better but really expensive. My advice is, get the memory foam of your choice ( in 3" or 4") and put a layer of higher density foam under it.

Faris · Sep 12, 2011

A solution I recently stumbled upon:

Buy cheap open-cell foam from a supplier. Get it just a bit thinner than you need.
Go buy a few 1/2" closed-cell foam sleeping pads for $3 each.
Put a layer or two of the closed-cell foam under the open-cell foam.

The closed-cell foam provides a waterproof barrier so the thicker open-cell foam doesn't act like a sponge. Also, it is more rigid so it does a good job of smoothing out the cushion if, for example, you need to lay it over a bump or ridge.

If you like the feel of it, you can put the closed-cell on top, and this makes a firmer mattress, and works well to prevent hips, shoulders, etc. from digging in to the hard surface below. If you weren't concerned about trapping moisture, you could sandwich the open-cell foam between two layers of closed-cell foam, but I think this is asking for mildew.

I was able to replace all of my foam in this manner for around $80-$85, it is wicked comfortable, and does not absorb moisture that condenses on hard surfaces overnight. I like the feel more than memory foam, and it is much lighter if that's a concern.

MrBill_FLL · Sep 12, 2011

New closed cell foam is the best. $$$

-but I'm cheap... so I ended up paying 3x... don't do that!

1st I tried a air mattress. awesome, but too tall.
2nd I tried a 1.5" memory foam topper. very soft and hot.
3rd I added a pillow top mattress pad (cal king). ok but I still bottomed out. rolling over or on my side. finally I got 4" of open cell and its pretty good. I think I might have 2 or 3 of the blue closed cell sleeping bag pads ($6) you see at WallyWorld under there. (1/4" thick)

I did cut and slip the blue sleeping pads under the cockpit seat cushions, and they helped.

I think the trick setup is high density on the bottom thin layer, med thickest layer, and low density on top, thin...

I forget where I read it, but a custom marine mattress is a sandwich, of multi density foams. good ones feel just like a 4 seasons bed and prices to match...

I should have just got new closed cell foam in the beginning.

Cruiser1 · Sep 12, 2011

The following site explains the difference between Weight (Density) and Hardness in foam. Just beware it is an Australian site and I am not sure the method of measuring hardness is the same in all countries. Weight numbers will depend on the country's measurment system - imperial or metric.
http://www.dymanfoams.com.au/techdata.php.

I am getting this crowd to do my starboard cushion foam in 35/230 ($55 cut to size) and my port side cushion foam in 35/200 ($100 cut to size), based on their recommendation. They will all be 75mm thick. I will use these as a trial before getting any others made up. The 35/230 is about 20% more in cost than the 35/200.

This crowd are major suppliers to the furniture and industrial trade. They supply foam for home funiture, industrial furiture, bus seats, etc. They had a board with 100mm squares of the various quality foams on it so you could actually feel the differences. I must admit it felt like I needed much firmer foam that what they where advising but I figure they get a lot of feedback and probably have a good idea of what most people want v's need. Obviously a lot will depend on personal preferences along the lines of preferring a hard, firm or soft bed matress.

If you can locate a major industrial foam manufacturer nearby is may be worth having a talk with them.

Sumner · Sep 12, 2011

doehunter said:
Thanks,
I'll probably be ordering in a few days.
so, to make sure,
get the 3" to go inside the berth and seat cushion covers?
The reason I'm asking is because the admiral says our couch cushion foam is thicker than it is when it's inside. It's a bear to put back in after washing the covers.
Jim

First off any of us giving you an answer is a crap shoot for you. We all have different preferences, so it it real hard for me to tell someone else what will work best for them.

The close cell foam won't soak up water, but it is way to hard for us. It is like the stuff they make PFD's and wrestling mats out of. I see no need for it in the cabin as it shouldn't get wet there. In the cockpit yes, but for us it is too hard to be sitting on all day, day after day on a trip.

For the cockpit we have been really happy with the ....

.... dryfast in 3 inch thickness that we bought...

http://www.foamreplacement.com/seatcushion/outdoor.html

If it does get wet it dries very fast and it is so much better than the soggy cushions we had that were original. Also it just doesn't seem to be wet from dew like the old ones. We also used...

http://purplesagetradingpost.com/sumner/macgregor2/outside-31-a.html

...an open fabric that helps the whole process. This foam is stiff when you sit on it, but you kind of sink in and we have found it comfortable for day after day use in the cockpit and is what we will use along with the same fabric in the Endeavour when we make new cockpit cushions for it.

We would not like it to sleep on, but I would use it for the cabin cushions.

We used the 3 inch in the V-berth and for the cabin seats. We used the highest density lux high quality they had that I mentioned in the other post. We love it for the boat and as I said before or now using it at home also. We have a sheet of plywood over the bed's two mattresses and the lux on top of that and are sleeping really well now both places. But as I said we love it someone else might not. We like a firm mattress.

3 inches of the same has been good in the cabin for Ruth, but I don't like it quite as well there. I'm 6-1 and 160 lbs. and have a boney butt. We spend ever night and some days in the cabin so are on those cushions a lot. For the Endeavour the cabin cushions will be the 3 inch lux like in the berth since they also make into a bed, but for the cushion at the Nav. Station I'm going to use the 3 inch with 1 inch of the dryfast under it and might do the same for the other cabin seats. That will make it act like what some of the others have mentioned.

I don't have my boney butt going through the 3 inch dryfast in the cockpit, but we don't want that as the top foam inside. The Foam Factory will send you samples but they are so small that it is hard to tell how they will act.

Good luck,

Sum

Our Endeavour 37

Our Trips to Utah, Idaho, Canada, Florida

Our MacGregor S Pages

Mac-Venture Links

timebandit · Sep 13, 2011

I went a different way and installed something called R Gard under the stock foam.

I used 1 inch and just slipped it under the stock foam and it was way better than the stock stuff but dont walk on it.

R Gard is a sheet of styrofoam with a vapor film on both sides so you just cut it with a hack saw blade, wipe the loose little balls off and insert under the stock foam, what a difference.

It floats real good too!

Sumner · Sep 13, 2011

One other suggestion I would make for someone that is replacing the foam in the V-berth or aft berth is to cut....

http://purplesagetradingpost.com/sumner/macgregor/inside-5.html

.... the foam side to side vs. the factory lengthwise. We did that in the V-berth and would do it in the aft berth if we had foam there. I think TB also did that. It is lots easier to lay on and also makes getting to ...

http://purplesagetradingpost.com/sumner/macgregor2/inside-16-a.html

.....the access hatches under the bedding. Just lift the section of foam up over the hatch you want to get to.

Cut the foam so that a cut isn't on a pressure point, your shoulder, hips or knees and you will never feel the joint cuts. Note above that our V-berth is in 3 sections. That might not work on the stock length V-berth. 2 might be better,

Sum

Our Endeavour 37

Our Trips to Utah,

Idaho, Canada, Florida

Our MacGregor S Pages

Mac-Venture Links

Kestle · Sep 13, 2011

We just added the $150 memory foam we got at Costco under the original cushions and love it! My only issue is that it is damp on the underside if left down, so baring another solution, we just leave it up vertically against the liner when gone.

I would like to find a method to have air circulate under it so the moisture wouldn't build...

Jeff

timebandit · Sep 14, 2011

This is what a lot of sailors use

Dri-DekCategories : Maintenance: Flooring: Dri-Dek

enlarge image

Dri-Dek ® Deck Tile

Creates a Ventilated Surface to Keep Gear Dry

Dimensions: 12" x 12"

Specify Color

Item #: 752942Manufacturer: KendallShipping Weight: 1.00 Lbs.

Our Price:$4.99
Please Make A Selection Tile / Almond ( $4.99 ) * In stock*Tile / Blue ( $4.99 ) * In stock*Tile / White ( $4.99 ) * In stock* Quantity

Description

Dri-Dek® is an extremely durable, ventilated surface designed to keep stowed gear dry and free from mold, mildew, and musty odors. Just interlock the rigid yet flexible 12" x 12" tiles to cover an area of any size. Add Dri-Dek® tile edges and corners for a finished look. Tiles can also be cut with a utility knife for a custom fit.
Features:

Each square has a perforated, non-skid surface
Supportive feet on the bottom of the tiles allow water to drain away from stowed gear
Oxy-B1 vinyl material is resistant to bacteria, mold, and mildew
Durable tiles are flame and chemical resistant
Color will not fade in the sun
Easy to clean - just spray down with the hose

Applications:

Ideal for lining the bottoms of your compartments, cabinets, or lockers
Use beneath bedding and cushions
Keep dock lines, stowed cushions, and life preservers smelling fresher and lasting longer
Put beneath anchors, gas tanks, or loose equipment to protect wood and fiberglass surfaces
Use under sensitive electronic equipment to absorb the impact from rough seas
Outfit the helm - Dri-Dek is ideal for relieving the back-breaking pain caused by piloting all day long

Kestle said:
We just added the $150 memory foam we got at Costco under the original cushions and love it! My only issue is that it is damp on the underside if left down, so baring another solution, we just leave it up vertically against the liner when gone.

I would like to find a method to have air circulate under it so the moisture wouldn't build...

Jeff

Kestle · Sep 16, 2011

Excellent idea. Many, many thanks!

Jeff

vizwhiz · Sep 18, 2011

We just bought foam for our S. Followed Sumner's advice about using the FoamFactory, and had a great experience. The guy who was cutting my foam even called me because he had a question about what I had ordered. Price was great.

However, we bought the 3" thickness of the plain ol' cheap stuff foam. We got it home, let it sit out several days after unwrapping it (very important to let it flex back to full size!) and then cut it to fit. We did not have any cushions in our boat (long story, don't ask), so we are starting from scratch and didn't want to invest heavily until we had a chance to use the boat and the cabin a lot and find out how it all works, how it feels, and what we wanted to change. So far we don't have the cushions covered, but that'll be coming soon enough...we spent some time laying around on the foam uncovered to see how well it supported us, and it seemed to do fine.

Cuts great with an electric knife...just remember to keep it perpendicular to the foam (if you tilt it, it cuts on an angle just as fast so you can't tell...)

flynfol · Sep 20, 2011

We wrapped our cushions in dacron before installing in the covers. Makes it easier and breathes better too.

Kestle · Sep 20, 2011

Seriously, do you run an upholstery store? They look great...

Jeff

Replacing foam in the cushions

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