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The wife is dead set against "hacking up" (her words) the existing mattress, so I'm going to have to wait to check what's inside until Thursday. She has to work, so I'll have time. I did check out the review on Sleepopolis, he shows what is inside the Tempur Pedic.
The existing cover is zippered, and separates into top and bottom, you can either buy a replacement top, or the whole cover.
I guess I see two potential issues - I saw one photo where there's a sheet of some material over the top that is glued to the sides, and I wouldn't be able to re-glue it to the side where I cut it. The other issue would be if they did something with the newer mattresses to make the edge firmer, and only one edge would be firm. I have the 2.0 version of the mattress with the gray cover, not the original with the tan cover.
From the sleepopolis photos / video, it looks like all the layers are glued together, so it wouldn't be easy to separate the layers to add wood, so maybe that's out. I'm also wondering if what makes the firmer bed firmer is the foam is denser. But still, buying one twin xl is half the price of buying two, or I could just buy a conventional firm mattress for my side.
I did find a video of a guy cutting down a tempurpedic for a RV, he used an electric carving knife. He had to make two passes and they didn't line up perfect, but maybe once it's under the cover nobody would notice.
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