Chinook RV

Anyone have thoughts on where and what size/type when it comes to new foam? I don't want to order it online as I'm on the road. I can if I have to (and send it to a friend's place), but picking up in person would be better.

If you are talking about the usual polyurethane foam: Whether you pick it up in person at a foam shop, or order it online, there are a few things that may be helpful. Comfort and what people like is subjective, but there are objective numbers so once you know what you like you can use them to your advantage.

The first thing is foam density (usually expressed as something like "2 lb. foam"). This doesn't correspond directly to how soft or hard it is, but rather to quality level. Basically, a higher density foam has more "foam in the foam" and will last longer and just be better.

The second thing is firmness/softness, typically expressed in ILD (indentation load deflection). An 18 ILD foam is very soft; a 50 ILD foam is very firm.

So you could have a 1 lb. density 50 ILD foam and it would be very firm, but lower quality and not as long lasting. Conversely, a 4 lb. 18 ILD foam would be high quality and long lasting, but very soft.

What I like to do is make up layers. In the past I once ordered a 4" high quality foam piece for a bed and it was all 42 ILD. It ended up being too hard and there was no real good way to adjust it. Hence I now prefer layers. They tend to stick together pretty well, so once they are in the cover they act as one piece (or you can glue them together with foam glue). With the layers, it's possible to get some of the good points of more than one ILD of foam. They can also be rearranged to change things slightly if your preferences change. It typically doesn't cost any more (or it's very similar anyway) to get three 1" layers or one 3" layer. I've never glued mine together and haven't had any issue with the foam creeping.

So for example for a 4" couch/bed I might get two 1" layers of 45 ILD for the bottom (that way no bottoming out); then 1" of 30 ILD for the middle, then 1" of 18" ILD for the top (cushion). But that's just off the cuff and also reflects my preference. But you get the idea. I always go for high density as I like it to last a long time, and just like the quality of it.

Foambymail.com and foamorder.com are places I have heard of (I've bought both by mail and in person at various times but the place I bought from online only does latex now).

I think latex foam has similar ratings for ILD etc.

PS: For looks, if you don't want the resulting cushion to look like a foam box covered in fabric, there is batting (dacron I think?) that you can wrap around it before you put the cover on. I don't know as much about that specifically, but just the concept.

All good info, but can I get it at an arts and crafts place? Cheaper at 1 store vs another?

Oooo... that's a terrific idea about layering different densities. That would've been much better for my sofa than the so-called "medium density" 36 pound foam I used... which is just a tad too firm for my wife's tastes.

re: Dacron batting. Yes, need that and spray foam glue to round off the corners, fill the cloth cover, and add a bit of softness.

As for dimensions, especially thickness, remove and measure the foam itself, not the outside of the cushion. The batting alone can easily add a half inch on every side. The cover adds on too.

Length and width can be adjusted later using a knife, and/or gluing pieces side by side. The batting covers the joints,

As for prices, foam from a craft store like JoAnns will cost several times as much as from a foam outlet. That foamfactory.com seems reasonable, especially with free shipping over $75. That alone can save dozens of dollars.

(I bought all mine off eBay and Amazon, looking for the best deals. Took longer to amass everything that way, though.)