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Restoring a mattress for an antique bed isn’t something most people think about — until they need to. Whether it’s a family heirloom, a rare antique frame, or a custom piece with unique dimensions, finding a replacement mattress that fits just right can be a serious challenge.
That’s where a custom mattress build comes in.
At The Beloit Mattress Company, we recently had the opportunity to remake a mattress originally built in the 1930s for a 150-year-old antique frame with a wraparound headboard.
From sizing the coils to hand tufting and working around the notched corners, every detail mattered in bringing this piece of history back to life.
In this post, I’ll walk you through the full restoration process, show behind-the-scenes footage, and explain how we crafted a brand-new, handcrafted mattress that’s ready to last another hundred years.
Preserving History: The Story Behind the Antique Bed
This restoration wasn’t just about building a new mattress — it was about preserving a piece of history.
The original mattress we replaced was made by Simmons in the 1930s and had lasted nearly a century. Simmons was one of the leading American mattress manufacturers of the time, known for innovation and quality.
In fact, Simmons pioneered the use of pocketed coil spring technology — referred to back then as Marshall coils — which provided advanced support and durability for its era.
These coils, along with layers of cotton padding and a cotton ticking cover, were hand-assembled using traditional button tufting techniques.
Remarkably, even after almost 100 years, the internal structure of the mattress still held up fairly well — proof of the craftsmanship that went into the original build.
But this mattress wasn’t just old — it was custom-made to fit a 150-year-old antique bed frame with a distinctive wraparound headboard and notched corners. That notch, a small but critical feature, ensured the mattress could fit snugly within the curved woodwork of the bed.
Standard mattresses simply wouldn’t work in a frame like this. Without a custom solution, this beautiful antique could’ve easily become decorative rather than functional.
Heirloom furniture like this tells a story. Whether passed down through generations or discovered as a vintage treasure, it deserves to be lived with — not just looked at. Restoring and reusing antique beds with the right custom mattress solution allows families to honor that history while enjoying modern comfort.
We believe craftsmanship should support preservation. By respecting traditional techniques and applying them to custom builds, we’re helping customers keep these meaningful pieces part of their everyday lives without compromising comfort or fit.
The Challenge: Replacing a Century-Old Antique Bed
Replacing a nearly 100-year-old mattress isn’t as simple as swapping it out for a new one, especially when it was made to fit a custom antique bed with a unique design.
The original mattress, built in 1936, was showing its age. The cotton ticking cover had begun to rot, the padding had compressed over time, and while the pocketed coils weren’t in terrible shape considering their age, they had clearly worn down.
Still, the mattress had served its purpose admirably — lasting nearly a century thanks to quality materials and traditional construction methods like button tufting and natural cotton layers.
But the bigger challenge was the shape.
The 150-year-old bed frame featured a wraparound headboard that required a precise notch in both the mattress and foundation. This structural detail ensured the mattress would sit securely in place. A standard mattress simply wouldn’t do. Without that notch, the piece wouldn’t function as intended and would risk damaging the frame—or the user’s comfort.
No mass-produced mattress is going to account for a carved wooden headboard design from the 1800s. That’s where a custom mattress solution becomes essential.
To recreate the mattress, we had to size the spring system precisely, cut notches into both the mattress and the foundation, and hand-build everything from the frame up to match the original. Every detail—from the corner stitch work to the final tufting—had to be carefully measured and constructed to fit the antique bed perfectly.
The Custom Mattress Process
Creating a mattress for a 150-year-old antique bed takes skill, precision, and attention to every detail. Watch the full video above to see the entire process in action, but here’s a quick step-by-step summary of how we brought this custom bed to life. Every step was handcrafted to ensure this custom bed matched the original — and lasts for decades to come.
Step 1 – Disassembly
We opened up the original 1936 Simmons Beautyrest mattresses to inspect the cotton layers, ticking, and pocketed coils.
Step 2 – Foundation Build
We built a custom foundation and carefully notched it to fit the bed’s wraparound headboard.
Step 3 – Spring System Sizing
We cut the spring system to size, making sure it matched the original dimensions and contours.
Step 4 – Cotton Layering
We layered multiple sheets of natural cotton over the coils to build support and comfort.
Step 5 – Tape Edging
We tape-edged the mattress, taking extra care to sew the tight inside corners by hand.
Step 6 – Hand Tufting
We hand-tufted the mattress, threading straps through each layer to lock everything in place.
Step 7 – Final Assembly
Every step was handcrafted to ensure this custom bed matched the original — and lasts for decades to come.
Why Hand Tufting and Cotton Matter
When it comes to building a mattress that’s meant to last, materials and technique make all the difference. That’s why we still use traditional methods like hand tufting and natural cotton padding..
Hand tufting isn’t just for looks. It’s a time-tested technique that runs straps through the entire mattress, compressing the layers and locking them into place. This prevents shifting, sagging, and bunching over time — key to keeping the mattress supportive and comfortable for decades.
The original Simmons mattresses used this method, and we followed the same approach to ensure long-term durability. We also chose natural cotton padding, just like the original build. Cotton is breathable, supportive, and resilient, making it an ideal material for both comfort and longevity.
These details may take more time, but they’re worth it. They’re what turn a mattress into a legacy — built not just for today, but for the next generation.
Thinking About Restoring Your Antique Bed or Have a Custom Need?
If you have an antique bed or a one-of-a-kind frame that no standard mattress will fit, you don’t have to settle for putting it in storage or using it just for show. With a handcrafted custom mattress solution, you can preserve the charm and character of your heirloom furniture and enjoy everyday comfort, too.
At The Beloit Mattress Company, we specialize in building custom size mattresses that honor the past while meeting today’s standards for quality and support, and we’ve been building mattresses since 1929.
Whether it’s a century-old headboard with unique dimensions or a family treasure passed down through generations, we can help you bring it back to life. If you’re ready to restore your antique bed — or need a custom mattress for any unique space — request a fast & free quote today. We’d love to help you build something timeless.
