If you are talking closed cell foam pad, chopping one up to what you want isn't a very complex DIY project. People have discussed materials to use. If you just want closed cell foam, people usually recommend picking a cheap one up in the camping section at Walmart. If you want additional insulation the hardware stores cell foam insulation with a reflective backing. I think Bill Stephenson was using something like this?

If you want an inflatable pad, now you are talking a real DIY project. I haven't looked into it much, but I understand Bender (who used to run Kookabay and produce very popular sleeping pads) discussed many of his techniques on BPL. I think it comes down to the right materials and a hot iron. The most challenging part is getting the valve glued.


Edited by BZH (08/09/12 02:08 PM)
Edit Reason: added an n't to say what I actually meant