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My husband and I made these large ironing boards 24" x 60" for quilters in our area. The cost of materials is less than $30. This includes two layers of Warm & Natural batting and 1 7/8 yards of Drill (heavier woven) from Jo-Ann's (use 50% coupons). I don't recommend the silver ironing board cover as it stays hot too long.
24" wide board - cut Drill 66" x 30"
Warm and Natural batting - cut 64" x 28"
Keep the Drill that you cut off the width. Cut in sections and use on top of your board in the area which gets the most use. It is extra protection against scorching if you press seams while piecing in one particular area of the board.
Press the Drill fabric giving attention to the fold. Do not spray with water. Don't ever wash Drill. It shrinks and the wrinkles won't iron out.
Use an electric staple gun with 3/8" staples. (Take the old staples out with a screwdriver.)
After stapling the batting, staple a long side of the Drill with the selvage edge first starting in the middle. Pull the fabric taut lengthwise as you staple toward the ends. Next staple the opposite side folding under the edge so it covers the padding. (It may need to be trimmed.) Be sure to pull it taut across the width and length when stapling.
Staple the short ends keeping the fabric taut while stapling. Trim the corners, fold under, and make three folds on each side of the right angle. Staple.