This project involved creating a custom mattress for a 2020 Thor Chateau 27R motorhome. The mattress needed to fit in a slide-out compartment, presenting specific design challenges. Fortunately, our RV and motorhome expertise enables our team to handle these challenges with ease.
Design Challenges
1. Assessing the Slide-Out Mechanism: We began by evaluating the slide-out mechanism of the 2020 Thor Chateau 27R. This helped us understand how the mattress needed to fold completely.
2. Designing a Specialized Hinge: After the assessment, we developed a specialized hinge design for the mattress to function effectively in the slide-out compartment. The mattress is 74 inches long and split into two sections. The top section measures 48 inches, while the bottom section measures 26 inches. The total width of the mattress is 72 inches.
3. Determining Thickness Requirements: The top of the mattress is 5.5 inches thick, followed by the hinge. The bottom section measures 8.5 inches thick. We carefully measured these thicknesses for a proper fit.
4. Seamless Integration: Finally, we focused on smoothly integrating the different thicknesses. This made the mattress fit perfectly and provided maximum comfort while on the road.
Outcome
We used our specialized custom mattress construction method for the 2020 Thor Chateau 27R motorhome. Our unique design creates a superior product compared to other manufacturers. The hinge location is extremely durable and sturdy, remaining virtually undetectable when lying on it.
We completed the construction in just a few days. We then delivered the finished mattress to our client, who had a very happy customer pick up the motorhome. Our goal with commercial clients is to meet deadlines with a top-quality product. We also provide a hands-off experience, allowing them to focus on their clients’ needs.
We welcome any dealer or parts representative to reach out to us the next time they need a mattress and find out what we can offer!
