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I am about 90% finished now.
I found a mattress in Ikea that is almost perfect, the only problem is that it does not fold very well over the back of the chair when folded up. I may have to split it.
I used 40x40 extrusion because I had a load of it lying around. If I was buying from scartch I would go for 30x30.
Thinking about buying the cover for the mattress which would tidy it up when in seat configuration.
I am currently constructing a bed from aluminium extrusion, I'll post some pics when done.