My apologies to the board and
@1leglance @jhmoore @Scoutman @86scotty @CSG @LandCruiserPhil and
@towee for not reporting back. Got caught up with stuff and forgot about this thread.
Short version: Exped replaced the mattress.
Long version: Their initial assessment of the tear (pictured at beginning of this thread) was that it was fixable on their end so they fixed it. FWIW, I fixed it using the enclosed kit and they removed my fix to look at the failure. They said I did a great job fixing it, and then they proceeded to fix it again. After they fixed it they filled it with air and tested it in a water tub. When they tested it in the water tub they said they found a leak in a seam. Because they found a leak in a seam it is considered an unrepairable failure and at that point they replaced the mattress with a new one. It was an approximate 3 week turn around. As mentioned earlier Exped wanted me to pay shipping to them, but they ended paying shipping both ways (I was appreciative of that).
I was pleased they sent out a new mattress, I was not so pleased with their initial plan to fix the failure and not replace the mattress considering it was brand new. I was a little surprised considering how good their reputation is that this mattress had this major failure and then on top of that had a second failure - leak in a seam. I am chalking it up to getting a fluke bad mattress.
Overall, very happy with Exped.
