Jennifer23

The problem with fusible is that it softens every time you iron over it, so eventually it un-repairs itself.

I would probably put the fusible in (but not fuse it yet), then hand-stitch the edges together, then fuse to reinforce the stitching.

I might also consider just re-covering the whole thing - cut fabric bigger than the ironing surface, hem the edge along the centre (where the mat/ironing surface folds), and wrap around and duct tape to the back on the other three sides. The best method is probably the one that suits you best aesthetically.

lots2do

I cut mine too. It's not very big. I just ignore the cut and there hasn't been an issue. I did try folding it in half but then the heat from the iron 'gets' to the cutting side.

QuiltnLady1

You can get ironing board fabric at JoAnn's -- I'd put a piece of that over the whole pad and just hand stitch it to the sides (I would need to use pliers to pull the needle through).

KwiltyKahy

This was my first thought, too. Good luck