I have 5 pieces of 24"x72" foam (4" thick) that I ordered from Rochfordsupply.com . Cost including shipping was $220. I Cut all of my new cushions this morning except for the one for the top bunk. It wasn't until after I'd ordered all 4" foam that I took that old upholstery off the top bunk and realized the stock foam there is only 3" thick. The plywood underneath makes up the difference in thickness.
My mother-in-law will be making us new upholstery out of some outdoor rated fabric we bought last weekend. My options for the top bunk are....
1. Use the 4" foam for the top bunk and have the upholstery made to accommodate the extra thickness of the wood plus 4" foam. I AM CONCERNED THIS WILL CAUSE SOME SORT OF ISSUE, when the top bunk is folded down for the gaucho back. The top bunk was not connected when I bought the trailer and I don't have the hinges to attach it for experimental/testing/measuring purposes.
2. Use the 4" foam and have the new upholstery made for 3" foam and then just fight like crazy to get the 4" foam and the wood into the new cover. It might be that this just will prove impossible.
3. Order the proper 3" foam and deal with the EXTRA COST. Try to sell the "extra" piece of 4" foam.
Hopefully some of you will have some insight into this matter.
For the record the foam I ordered from Rochfordsupply.com is the one listed as "most popular" and has been used by many on this forum. It is significantly softer, floppier, less dense, easier to tear and seems to be inferior in quality to the stock foam. However, it's not cover/filled with mildew and mold and 32 years worth of other peoples dead skin cells. It also cost quite a bit less than having Scamp
$hip the stock foam, its also much cheaper than getting the foam locally ($400). I used high quality $$ spray adhesive to make a the foam a bit longer for the lower bunk. The adhesive cannot be "felt" in the foam. I was surprised to find that many of my stock 32 year old foam cushions we're pieced together with spray adhesive as well.
Despite the fact that it seems lower quality than the stock foam- I bet it will be tons MORE COMFORTABLE than the stock foam when it comes to sleeping. If we can deal with sleeping over the dinette cushion "seams" then we may just be able to sleep right on top of this foam without adding an additional foam topper.