I'm doing the exact same thing now. Found a place out in MI that will custom make them to your spec. I intend to send mine to them so they can use it as a template. My original "mattress" is just 3 " of firm foam. I will probably go with 5 inch foam and 1 or 2" of memory foam on top. This place will also provide zippered cases to fit... but I believe only for standard sizes. Probably will have to send the mattress to a custom shop else where to get the slip covers made... or, we might just use a washable sheet tucked in around it in the interim.
If you don't want to spend a lot on a custom mattress we had one of the 'Tufted Toppers' made a couple years ago that goes on top of the foam mattress that came with the boat and have been very happy with it. Reasonable price and it made a big difference in comfort.
We went to a local mattress company with a paper template, to include bevel angles. No problem at all. Not real cheap, but the best sleeping mattress I've got. Local seamstress made some custom fitted sheets for next to nothing. Mattress is 5" thick including a memory foam component. Pricing include vinyl on the bottom & a zippered case.
I have used Hand Crafted Mattress on my previous boat. It was the best decision I made. It was made with tallalay foam. We used it for 9 years. Never a problem. At that time they were approximately $850 a mattress. I had two made. My present mattress is HCM as well. Give them a call.
I also have the HCm mattress in the master berth. At home we sleep on a TemperPedic and we sleep well on the boat. What I like was that they came out and measured and I wasn't left to do it myself. About $900 for a queen master.
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