I did something similar to you, except I used progressively less dense layers of latex (also from foamorder.com). CalKing rather than anything larger, but I've considered larger and I've been thinking it's better to make an Emperor or Caesar size formed from two halves.
it's been 10 years btw since I build mine. There's a slight give in the densest lower layer but it's held up enough that I still only really need to replace the top layer to get it back up to snuff.
My question: how in the hell do you afford sheets that size? lol
Foamorder's max latex size is king or cal king but they were willing to glue a bunch of chunks together for me. I'm not sure what glue they used (presumably latex?) but it's held without issue. I cannot feel the dividing between the latex chunks under the buckling gel while in the bed.
>sheets
I ordered two sets of bamboo bedsheets from that Advanced Bedding and they've lasted me all this time without ripping or stretching or anything. I usually leave the comforter at the foot of the bed when I get up so that probably helped them air out. Can't remember how much they cost but you can run the numbers on their site.
it's been 10 years btw since I build mine. There's a slight give in the densest lower layer but it's held up enough that I still only really need to replace the top layer to get it back up to snuff.
My question: how in the hell do you afford sheets that size? lol