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Sat Jan 09, 2010 9:24 pm

Does anyone know what the original thickness is for both the bottom seat/bed and the top bed? I'm looking at replacing the foam all around.

I measured the bottom and it looks like the seat foam is 3" thick and the engine cover is 2.5" I'm not sure if that's the original thickness or if that's what it's settled to after 40 years.

Also has anyone replaced the foam on the upper bed with anything thicker? I'm wondering if you can get the bed to fold shut with say 3" foam. Thanks.

Sun Jan 10, 2010 12:36 am

Can't help with the top bunk, but imagine there's not much extra thickness to work with. 3" foam up there is unlikely. We fold up a 2.5" thick memory foam topper in the space behind where the bed folds onto itself - really helps soften up the top mattress.

For the bottom foam, my 34 year old foam measured just like yours. I added 1/2" to both with the new foam - fit great but can't imagine going much thicker. This was using a laminated high density foam with medium firmness base and 1" softer 'topper' - plenty of support for seated passengers & nice and soft for sleeping. We've always slept up in the penthouse but may have to move the bedroom downstairs.

Sun Jan 10, 2010 6:19 pm

I was able to find a local foam maker to make new foam for my Westfalia.
I had to choose from different grades of softness... I have found different
methods of rating foam,, this company uses 2545 to rate this foam.. it is
slightly "harder" than the Lady recommended.. but way softer than the grade
I "thought" would be good.

Turns out to be perfect ! :-) imho
http://www.customfoam.com/store.html

For the archives,, the foam I got measured.. inches
25 x 46 x 2 upper bed
48 x 46 x 2 upper bed
48 x 35.5 x 2.5 over the engine , they cut it to the shape
18.5 x 54 x 3 seat
21 x 54 x 3 seat

Sun Jan 10, 2010 7:36 pm

for the bottom bed don't forget to glue the foam to the wood when replacing it or it will move around after the cover is on, even when stretched tight.

Mon Jan 25, 2010 10:42 pm

I ended up ordering from foamorder.com. Here's a couple of pictures for comparison if anyone has this same questions in the future.

Left, 3" EverFlex V44 Medium foam. Right, original seat back foam.

Left, 2.5" EverFlex V54 Medium-Firm foam. Right, original engine cover foam.

I ordered two different densities of foam because I thought that it might be better to have the extra firmness for the thinner section of the bed. I also wanted to feel how it felt before committing to buying the foam for the upper bed where I plan to spend most nights. Unfortunately the medium density feels nice, but like it will bottom out if it's any thinner than 3". And the medium firm density feels way to firm to sleep on.

Wed Jan 27, 2010 11:06 am

Useful posts. Thanks.

Please let us know on the bottom out issue on the lower density foam.

Wed Jan 27, 2010 11:39 am

I'm going to go with the medium foam for the top and hope for the best. The medium-firm density is so firm it feels like laying on a carpet. I might look at getting a topper if it ends up bottoming out. I'll keep the thread updated :)

Wed Jan 27, 2010 5:58 pm

Thanks for the info benjamin, I've been looking for some on foam for a while.

Tue Feb 09, 2010 10:28 pm

My girlfriend and I reupholstered the rear seat this weekend. The foam sizes we ordered turned out perfect!

Here's the complete dimensions:
engine cover: 47"x36"x2.5"
seat bottom: 20"x42"x3"
seat back: 17.5"x42.5"x3"

I guess I should hold final judgment until they are back in the bus, but they LOOK great!

The fabric we used is from wolfsburgwest.com which is good quality. We used it to recover the seat and reused the original fabric for the engine cover. The second picture shows the two fabrics side by side, and despite looking exactly the same in the pic, the wolfsburgwest fabric is actually noticeably darker.

Here's a couple of tips for anyone who does the same thing:

1) the easiest way we found to cut the foam (for the engine cover) was with a hacksaw with a metal fine toothed blade
2) when stretching the fabric and stapling it to the seats, pull the fabric from the middle of the seat each time before you staple

Wed Feb 10, 2010 9:42 am

Those look fantastic! Please do get back to us with your thoughts on the foam firmness once you've had the chance to break 'em in.

Wed Feb 10, 2010 9:51 am

an electric carving knife (like the one you got as a wedding present, and forgot all about) , works absolutely amazing to cut foam. it cuts straight and effortlessly.

just thought i'd throw that out there

Wed Feb 10, 2010 6:17 pm

benjamin.smith wrote:

The fabric we used is from wolfsburgwest.com which is good quality. We used it to recover the seat and reused the original fabric for the engine cover. The second picture shows the two fabrics side by side, and despite looking exactly the same in the pic, the wolfsburgwest fabric is actually noticeably darker.

I wonder if the difference is due to the old fabric being a little faded. I did the same thing with the brown Wolfsburgwest fabric, and now I can't remember which is the old and which is the new. For the brown at least, it's a perfect match.

Wed Feb 10, 2010 9:35 pm

would washing the original fabric fade much?. My fabrics have no holes but are a bit dirty and has stains.

Wed Feb 10, 2010 10:00 pm

I doubt washing them would make the fabric fade much. The engine cover fabric we removed and washed in the bath tub using woolite. It was DIRTY. It took three washings before the water didn't look black afterward. It did come out looking a slightly lighter color, but I assume thats from the lack of dirt :)

Wed Feb 10, 2010 10:20 pm

No worries washing the fabric. Put it through a couple cycles in the washing machine and let it air dry. Colors will brighten up a bit but won't fade.

Sat Feb 12, 2011 9:03 am

How much did you pay for all the faom? Thanks

benjamin.smith wrote: My girlfriend and I reupholstered the rear seat this weekend. The foam sizes we ordered turned out perfect!

Here's the complete dimensions:
engine cover: 47"x36"x2.5"
seat bottom: 20"x42"x3"
seat back: 17.5"x42.5"x3"

I guess I should hold final judgment until they are back in the bus, but they LOOK great!

The fabric we used is from wolfsburgwest.com which is good quality. We used it to recover the seat and reused the original fabric for the engine cover. The second picture shows the two fabrics side by side, and despite looking exactly the same in the pic, the wolfsburgwest fabric is actually noticeably darker.

Here's a couple of tips for anyone who does the same thing:

1) the easiest way we found to cut the foam (for the engine cover) was with a hacksaw with a metal fine toothed blade
2) when stretching the fabric and stapling it to the seats, pull the fabric from the middle of the seat each time before you staple

Thu Mar 31, 2011 3:09 pm

will 3" foam fit in the over-the-engine mattress cover, instead of 2.5"?

Fri Apr 01, 2011 12:42 pm

anybody replaced their stock foam coushins with memory foam?? That would bee ooooober cool for the top bunk!!

hmm...off to joann fabrics....

Sat Apr 02, 2011 1:09 pm

these self- inflating camping mats seem pretty cool to lay on top of bed while sleeping....when your done just release valve and roll up....found a few that are 2 1/2 inches thick (2 " high density foam w/ 1/2 " memory )
the deluxes are about 50"x 75"

Tue Apr 12, 2011 8:32 am

how much foam should hang over the edges of the plywood?