Frank Brownie started this business in 1939 repairing mattresses in his Christchurch garage, and odd shapes have been part of the job ever since. Caravan beds, boat berths, motorhome cab-overs, truck sleepers, antique frames: if it's a size nobody sells, we make it. Here's how it works and what to think about before you order.
Quick answer
- We make custom innerspring mattresses to your measurements in our Christchurch factory: odd sizes, cut-off corners, curved ends.
- For a rectangle we need length, width and the depth you can fit. For anything else we need an accurate pattern of the shape, on paper or cardboard.
- Pick the feel the same way you would at home. The Monarch is our usual starting point.
- Custom sizes are excluded from the 100-night exchange, so measure twice.
- Standard sheets won't fit. Plan for that.
Why a standard mattress rarely works in a caravan
Caravan and motorhome beds are built to the van, not to a mattress chart. The common problems: a bed that's 10 cm shorter than a Double, a corner cut away for a walkway or wardrobe, a curved end against the wall of the van, or a platform that's 1.4 m wide where a Double is 1.37 m and a Queen is 1.53 m. Jam a standard mattress in and it either rides up the walls, leaves a cold gap you fall into, or won't go in at all. Cut a standard mattress down and you've cut through the border wire and voided the warranty.
The alternative is a mattress made to the bed. Same spring unit and comfort layers as our standard beds, built to your shape.
What we can make
- Any length and width, including sizes between the standards and one-off dimensions for island beds.
- Cut-off or angled corners to clear a door or cupboard.
- Curved ends for boats and the rounded rear of some vans.
- Mattresses for antique and imported frames, cots and bunks in odd sizes.
- Reduced depth where overhead lockers or a bed that lifts for storage limit the height.
Need the mattress in two pieces so one end lifts for storage access, or something else we haven't listed? Ask. If we can't do it we'll tell you.
Choosing the feel
A mattress that fits perfectly but is too firm is still a bad night's sleep. Choose the feel the way you would for your bed at home, by how you sleep on it. Most custom orders are built on one of these:
- Monarch: medium-firm, double-sided so you can flip it, 220 mm deep. Our go-to for caravans, boats and antique beds; the product page says as much.
- Medicoil Firm: firm, 185 mm. The lower profile suits beds under lockers.
- Posture Plus: soft, double-sided, 255 mm. For people who find caravan beds too hard.
- iSleep Plush: a soft pocket spring in a foam box that bends, built for adjustable bases and also made in custom sizes. Worth asking about for a bed that folds or hinges.
Depth matters more in a van than in a house. Measure from the platform to the underside of any locker above it, and remember bedding adds a few centimetres. If you're short on height, tell us and we'll suggest the shallowest option that still sleeps well.
How to measure
- Strip the bed back to the platform.
- Measure length and width at both ends and in the middle. Vans are rarely square; use the smallest figures.
- Measure the available depth under any overhang.
- For a cut corner, measure how far the cut runs along each edge.
- For a curve or anything irregular, make a full-size pattern: tape newspaper or cardboard to the platform, trace the outline, mark which end is the head and which edge is against the wall, and bring it in or post it to us. An accurate pattern is the single thing that makes a custom job go smoothly.
- Take a photo of the bed from above with a tape measure in shot. It answers most of our follow-up questions.
Our size chart is useful for comparing what you've got with the standard sizes; sometimes a King Single or Long Single turns out to fit after all.
What it costs and how long it takes
A custom mattress is priced from the nearest standard size of the model you choose, plus a charge for the pattern work, so the starting point is on the product page. Every mattress we sell is made to order anyway, so a custom one isn't a special case in the factory; allow a few weeks, and tell us if you've got a trip booked. Delivery is $39 within 50 km of our stores and quoted on size elsewhere.
Two conditions to know before you order. Custom sizes are excluded from the 100 Nights Customer Satisfaction Guarantee, because we can't resell a mattress shaped for your van, so choose the feel carefully and lie on the standard version in store first. And standard fitted sheets won't fit an odd shape; most people use a flat sheet tucked, or have a fitted sheet altered.
What our customers say
From Justin in Nelson: "When I first bought my caravan, I really struggled to find a mattress that would fit into the awkward bedding space. With Brownies Mattress Direct, I didn't have to compromise quality for a custom made mattress size. The process was also made that much easier by Brownies staff, whose service was helpful, friendly and professional."
Already have a caravan mattress that's seen better days?
If the shape is right and the comfort has gone, we can often repair or recover it rather than replace it. Same-day repairs are available in Christchurch; elsewhere freight applies and it takes longer. Ring us before you throw it out.
Frequently asked questions
Is a custom caravan mattress worth it?
If you use the van more than a couple of weeks a year, yes. It's the difference between camping and sleeping.
Can you make an unusual shape?
Yes: cut corners, curves and odd sizes. We need a full-size pattern for anything that isn't a rectangle.
How do I measure?
Length and width at both ends and the middle, depth under any lockers, and a pattern for irregular shapes. Photos help.
Can I choose the firmness?
Yes. Choose the model and feel as you would for a house bed; the Monarch is the usual starting point.
Can I exchange it if it's wrong?
Custom sizes are excluded from the 100-night exchange, so we'll check measurements with you before we cut anything.
Send us the measurements
Use the contact form with your measurements and a photo, or bring the pattern into any store, and we'll quote and talk you through the options. More on the custom made beds page.
Related guides: Custom made beds · NZ mattress sizes · Best mattress firmness for every sleeping position
