To see how we got here, you may want to read this first,
Hunting for the perfect mattress.
or this
The following is the step by step photo construction of our new Sleep Innovations Mattress from Costco that appears to be what you would get if a Sleep Number Bed had an affair with a Tempur Pedic Mattress.
The first shot below is our new bed from Crate and Barrel. My wife loves it.

Then there is the warning about the memory foam smell. I had read a lot about this and was prepared for the worst. I have an extremely powerful sniffer that can pick up scents from across the house that others miss. I had to stick my nose into the foam to smell this warned of smell.

Here is the whole box. It was about four and some change tall.

This is the company name on the box.

Here is the mattress size. They also had all others including California king which I think is longer and narrower than a regular king but I am not sure.

This is why Americans better stop complaining and get to work twice as hard as they do now. Almost everything cool is made in China and we make what?

Here is the entire contents of the box laid out on the Crate and Barrel bed. Remember this mattress was around $600. I understand why some of the people who buy the Sleep Number bed freak out when they see the contents of the box that they just paid $3000 for. I have not actually put together a sleep number bed, but from my studies this appeared to be very similar, except with a thicker tempurpedic style mattress on top. See my foot in many of these photos for scale. (But I am not blaming anyone! ![]()

Here are the fancy instructions. These did not impress me and caused me to waste about half an hour because the pictures were not nearly as clear and cool as on this blog. This is the only picture of the little controller gizmos.

Here are more of the instructions. Why they don’t have a photo step by step online like this one is beyond me, or maybe they do and I just don’t know it?

Here is the mattress sock. To understand the construction of the whole thing, think of a thin sleeping bag with fabric about as thick as a sheet, with a bunch of stuff crammed into it. That is the construction of the whole mattress.

Here is the mattress sock unfolded and unzipped. I broke one of the zippers on the mattress sock by the way on the final zip, but the bed still works fine. When I get around to it I need to get a replacement sock. By the way, at the beginning of installation find the holes in the sock near the head of the bed. The directions don’t tell you to find them until the end when it is impossible to find them. This caused me to rush at the end because i wanted it done before I left for work. If I had found the holes at this point, it would have made it much easier, and possibly saved a zipper broken from me rushing.

The next item which are these foam 2 x 4 thingys’ were in the middle of the tempurpedic-like mattress material crepe. It was a pain to get them out just because I was running out of room.

Here are the foam board thingys laid out.

You fit the four foam things together to make some sort of a structure.

Then there is a fabric piece that wraps around the very outside of the foam boards that are now in that square above.

The corners lock together as if it gives them some structure, but basically the only real structure comes from the air you fill it up with at the end. Otherwise it was like building a crepe out of smaller crepes.

Here are all of the corners locked, with the fabric strip around the outside. I was never sure if I get the fabric strip just right or not, but it is a piece of fabric for gosh sakes, and I could never figure out what it was for anyway?

Then you flip over some flaps of the original sock to sort of hold the foam board thingys in place.

You then put a piece of foam with slits in it on the bottom. Later on you will realize those slits are for the cords from the air bladders.

Here is the air pump and one of the air bladders. It is a fricken air mattress! It is actually of apparently the same construction, and the same material as the Coleman air mattress I bought at Target a few years back.

Who’s ready to go camping! Yayyyyy!!!!

In many write ups about the Sleep Number bed I heard complaints about a foam wall between the air mattresses. In this case they made it wide, and it tapers down to be very narrow between the air mattresses. There is no hard edge on this center piece of foam anywhere, so I think they fixed the error that others had experienced in the Sleep Number bed.
You then take the cords under the mattress and thread them through the holes in the head of the sock, which are now impossible to find unless you found them at the beginning.
You can also see the final piece of memory foam that is about to be laid out over the mattress. I was rushing at this point so threw it on and started zipping. Then I folded the top part of the sock that you see folded over the headboard, and then zipped the whole thing up too fast and broke one of the zipper claps. The sock still works with just one zipper clasp.

With the new fancy sheets.

The early reports on this are heaven. From the first second it feels amazingly comfortable. We played with it and you can make it feel a little uphill or downhill if you fill one side more than the other.
If you way overfill the mattress it can make you feel like you are sleeping on a pod that you might fall off of, as one other writer mentioned.
For us, so far the bed is wonderful, and I will do a full write up on the sleeping on it soon.
As far as the construction goes.
This is a thick sheet sock with a piece of foam and some air mattresses in it. That is really it.
It makes much more sense to me than a big heavy traditional mattress which is going to compress and wear out after a few years anyway. It is also very easy to move and remove if necessary because it is mostly fabric and air.
How long will it last? I bet a few years, maybe five?
Would I have been happy paying $3000 for it? Hell no.
For $600 or $700 it reminds me more of an expensive jacket, but one that I will be wearing every night for 8 hours or more for the next three years.
My final evaluation will come after more sleeping, but from all the analysis I have so far I will give it two huge thumbs up.
To repeat my previous offer to Tempurpedic and Sleep Number. I notice that this blog is showing up very high in Google for your terms. So to be fair if you guys want to send me temporarily your best mattress to try, we can set it up in the guest room and I will be happy to give it a go and make an honest comparison. If it is better than the Costco one, then I will be happy to tell everyone that fact.
And to my readers, please continue to leave comments. This site is gathering a lot of stories about these beds where the writer (me) and the commenter’s have not financial stake in the outcome of this discussion.
Sleep Well!
dk
1 response so far ↓
jandrh // Mar 27, 2008 at 2:05 pm
We’ve been watching for your updated blog on the mattresses and are happy to see you got it set up finally. We ended up purchasing the same mattress from Costco also about 2 months ago. We love the air bed, but find this Novaform one from Costco to get very sloppy quickly. The sides send to bulge out quite badly and you end up feeling like you’re falling off the sides. The sides are very soft and are not firm enough to support the side and keep a neat looking mattress wall. The contruction is loose and the mattress just seems to feel sloppy far too soon. Is this something you noticed? Other than the lower quality construction this bed is great and we sleep better with the adjustible air bed than on any other mattress. We are looking into the Comfortaire mattress on nationwidemattress.com and may be replacing the Costco one with a Comfortaire. The Sleep Number beds we lay on in the store were not sloppy feeling like the Costco mattress. We don’t want to spend the money on the Sleep Number bed and Comfortaire is actually a middle priced between the Novaform (Costco) and Sleep Number mattresses. That’s been our experience so far. Have you noticed any of these issues that I mentioned with the construction?
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