Gracie Mat-Making Process (Do It Yourself!)

Now, more than ever, cleanliness of a jiu-jitsu school is paramount, and no where is cleanliness more important than the mats on which you and your students spend hours training on each day.

If you currently own a BJJ school, OR your dream is to open one, choosing what kind of mats to go with is one of the biggest decisions you’ll have to make: Do you go the pre-fab route OR do you do it yourself?

In this video, Rener breaks down the pros and cons for each method, and then he shows you the exact method currently being used at Gracie University Headquarters in Torrance, CA, to minimize cost, eliminate the cracks, and maximize cleanliness.

There are three primary components when it comes to the Gracie Mat Making Process: 1) Foam, 2) Vinyl, and 3) Wall Panels.

Foam Configurations
Best Quality Configuration: Polyethylene Foam (1.5”) under Ensolite Foam (0.5”)
Best Value Configuration (and great quality): Volara Foam (1 3/8”)
For specific pricing and best recommendations, call the foam master, Joe, at (310) 391-3626 or email joseph@foammart.com. Tell him you want the “Gracie Special” for an extra 10% off. He loves the jiu-jitsu connection!

Vinyl Mat Cover

For detailed pricing quotes call the vinyl legend, Bob Henderson, at 714-637-6300 or email him at Bob@Polyfabrics.com. He’s been doing this for decades and if you tell him you need a mat cover for a martial arts school, give him the dimensions, and he’ll take it from there.

Wall Panels

Each standard wall panel is made out of ½” plywood backing and 1.5” soft foam (ask Joe about the exact type we use at GU since I forgot). As for the upholstery that we use to cover the foam and connect it to the wall panel, you can use Ottortex Marine Vinyl which comes in 54”-wide rolls that can be found here in all kinds of colors: https://www.fabricwholesaledirect.com/products/marine-vinyl-fabric?variant=41720758028&gclid=EAIaIQobChMI8peQz5r_5wIVk-NkCh0VfQuKEAQYAyABEgJ5kvD_BwE

If you have any questions about materials or pricing, please contact the respective vinyl and foam experts as they will be able to help you better than we will.

Bonus Tips

-Duct Tape: When you are putting the foam down, use duct tape along the seams to prevent them from shifting under the vinyl over time.

-Wood Frame: You’ll need a wood frame around the perimeter of the mat in order to staple down the hook side of the Velcro. We used 2x4s, but depending on the thickness of the foam configuration you end up going with, you’ll want to adjust the thickness of the wood accordingly so that the height of the mat and the wood are similar.

-Wall Panels: Make sure you are consistent with how you fold the corners of the wall panel upholstery. Anyone with decent gift wrapping skills can help you make them look pretty. Also, make sure you screw the French cleat (z-bar) at the studs, if you just fixate them to the drywall, they won’t hold for long once the mat is hanging from in.

-Staple Gun: When it comes time to staple the Velcro down to the wood frame AND the upholstery to the plywood for the wall panels, you will want to use a high-power staple gun, preferably a Pneumatic Air Staple Gun (which you can rent or borrow).

Now that you’ve got the secrets to the best mat-making process in the industry, come learn the best jiu-jitsu programs on the planet! Remember, we only certify ONE school in each territory to utilize our systems, so the first step is to see if your territory is available, and if it is, you can reserve it for up to 12 months while you learn the material you’ll need for instructor certification. Check your territory availability at http://www.GracieInstructor.com.