I purchased and installed the Froli Star System, for my 560 CampInn. Focusing on the photo below, the Froli array in the foot area is 4 rows by 9 columns.
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This array is separate and not connected to the arrays on the right side of the photo, which cover storage bins. Spacing of the Froli base elements in the foot area is medium in both the row and column directions. Base element portions at the walls were trimmed off (using heavy duty scissors) to achieve a clean appearance. Otherwise tabs would have curved up the walls vertically. Using #8 x 5/8” screws, with washer, the foot area was anchored in 8 places (corners and 1/3 & 2/3 midepoints). Pilot holes were drilled into the base element (solid portion away from tabs or holes), then screwed down. Photo of the base element below will help explain differences between narrow, medium, and wide spacing.
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Froli is a German company, so dimensions are designed in millimeters. Base elements are symmetrical horizontally and vertically. Tabs are defined as the protrusions about ½ inch in from the ends of the cross. Narrow spacing is achieved by snapping the hole closest to the center onto the tab of the next base element. Medium is the middle hole and wide is the hole at the end. Use the embossed arrow on each piece (important) to align all the base elements in the same direction.
Base Elements Dimensions:
· Cross Length: 206 mm; 8-1/8”
· Tab to Narrow Hole: 148 mm; 5-13/16”
· Tab to Medium Hole: 163.5 mm ; 6-27/64”
· Tab to Wide Hole: 179 mm; 7-1/32”
· Hole Diameter 10 mm; 13/32”
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The protrusion in the center of the base element is the connection for the spring set. The spring set is simply pushed on this protrusion with the slot fittings in alignment and then rotating the spring set 90 degrees to secure it in place.
The dimensions for the tab to holes above is also the dimension of the spacing between spring sets. To ensure that last spring set has room to fit, 140 mm (minimum dimension), or 5-1/2 inches must be added to the calculated distance.
Totally array distances (add 140 mm for end spring sets):
· Narrow Spacing - 10 Spring Sets, 9 Spaces: (9x148) + 140 = 1472 = 58”
· Medium Spacing - 9 Spring Sets, 8 Spaces: (8x163.5) + 140 = 1448 = 57”
The bed in the CampInn is 58 inches wide, so spacing can be either narrow (10 spring sets) or medium (9 spring sets). As mentioned earlier the foot area in my trailer was set to medium spacing.
Next, the storage bin area is a challenge, especially if you desire to remove the lid from each of the four bins separately. Accurate measurements are key. My trailer has the spare tire stored in a bin, which means the two bins on the starboard side (passenger side of the trailer as it is pulled by the vehicle) are wider than the two on the port side.
The width and length dimensions for the bins is in the same orientation as the overall trailer length (hitch to galley) and width tire to tire). Bin lid dimensions are important for the fit of the Froli system. All the bins are the same length, and the bin lids are 21-3/4” long. The bin lid widths on the starboard side are 21-3/4” while only 18-3/8” on the port side.
The photo below shows the Froli arrays over the storage bins, with the lids partially removed for clarity. Each array is 4 rows by 5 columns using the narrow spacing in both directions. Froli recommended narrow spacing for my weight. I did not arrange the foot area with narrow spacing, because medium spacing is adequate for leg support.
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Each 4 x 5 array is attached by screws, with washers, near the four corners of each lid. Hence, each lid can be individually removed for access to the bin without lifting adjacent support arrays.
Actually all the base elements were assembled as one large 8 x 10 array. Then, after confirming the large array fit over the lids, it was cut into 4 separate 4 x 5 arrays. (Hint: Think, Plan and Measure as often as necessary, then repeat). Again base element excesses were trimmed away with scissors to eliminate conflicts with the walls and adjoining bins. On the near side of the photo (starboard side) there is only one column of spring sets beyond bin lid, while the port side has two columns of springs sets. I reasoned that Froli support is stronger and more robust when connected in larger rectangular arrays, which would not be the case for the areas between the bin lids and outer wall, where only single or double wide Froli strips can be used. There was a wood support by the cabin doors that resulted in two spring sets being slightly mis-shapened, but with the mattress in place it is not noticeable, nor is the Froli structure a concern.
My trailer has a slightly different dimension from the port wall to the bin lids, 8-1/4”, and starboard lids were 7-3/4” to the adjacent wall. You may not notice, but there is trailer floor construction of 2-3/4” wide between the couch and forward lids, and 2-1/4” wide between the forward and aft lids.
Some of the spring sets include (red) tensioners. I tend to sit on the edge of the bed at the door to put my shoes on, and felt the Froli array would support this area better with tensioners. The remaining tensioners are positioned in the hip area of a reposed (sleeping) person.
In summary the Froli Star System for a Queen Bed size includes 120 base elements, 120 spring sets, and 20 tensioners. The spring sets are proportioned to 100 firm units and 20 softer ones. The softer ones are recommended for the shoulder area. I used 36 sets in the foot area array, and 20 sets for each storage bin array, which comes to a total of 116 sets. I have 4 spares of base elements and spring sets should anything unforeseen happen to any of the Froli units.
As part of this project, I replaced my original CampInn mattress (an excellent OEM mattress) with an Inofia trifold, 4-inch-thick mattress. This mattress has 2-1/2 inches of high-density foam, sandwiched with 1-1/2 inches of memory foam on the top. I reasoned that accessing items from the storage bins would be easier with a folding mattress, as would making up the bed with clean sheets. I purchased the Froli for addition comfort that the cushiony Star System provides. Also, it replaced a hypervent that ensured breathable underlayment, but provided no cushion effect.
I would like to thank all the folks that have contributed to this thread. Without your knowledge it’s likely I wouldn’t have become aware of this option. The Froli Star System is distributed by Nickle Atlantic, who seem to be fully committed. It is a husband / wife operation, with maybe a couple other employees, but their company appears to be on good financial footing. There are three YouTube reviews that I am aware, and each offers purchase discounts. Nickle Atlantic honored the one I mentioned, and actually had a Christmas Holiday discount slightly better. I hope my experience with the install, with pictures and dimension, is helpful to Forum members looking to upgrade. Remember my CI is a 2015 Model 560, so I cannot provide dimension for the 550.