Join Date: Mar 2012
Location: Vancouver, BC
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Re: Foam for interior cushions??
I used a local foam place that sells good quality foam cheap. I did get zippers and poly-cotton covers. Cost about 1400$ including a big roll of closed celled foam(Volara) for insulating the entire hull. I got 2 V berth cushions(he figured out how to cut them both from a queen with no waste except the bevel on the edge for the hull)
two settee cushions(cut out of a single, with a 2" piece from another project added on the bottom) and 4 tapered backrest cushions. Settee cushions are firmer than the V-berth.
I discovered by accident that turning a V-berth cushion upside down gives a much more user friendly space, the taper sloping down to the hull creates an easier edge for tucking in sheets, anything dropped on the bed will naturally collect there to be picked up, and the bottom edge pressing firmly on the hull keeps the middle seam together.
While the covers won't look as fancy or last as long, they are hard to beat for 25$ each including materials and sewing.(50$ if they need shape added like V-berth cushions).
Sadly he won't use other materials, but apparently it's an insurance thing, as a foam seller who is only working with new materials from the shop, vs an upholsterer, his insurance alone is 1/10th as much per year, and his primary market is beds.
I priced out many places, including an upholsterer we have wholesale pricing with for OPBs who offered me a bit more of a break over his usual price, and still the foam place came in substantially cheaper. The upholsterer wanted the same price as I paid for everything, just for the foam.
Whatever you go with, I strongly recommend adding hypervent underneath, and insulating the tops of any lockers, or at least encapsulating the foam in plastic(I like the painters mask material) inside the covers.
Lifting brand new cushions after a month to find mold all over is no fun!