I have to agree that this is the laugh of the day. My BIL is an engineer, and he will always over analyze everything. But, what he comes up with is always top notch.
I solved my ironing board problem by just taking a chunk of plywood, don't even know what size it is, but it was big enough & I made it work. I took pillow ticking, made a pillow case for the board and pulled it over with some old bathtowels for padding. I won't attach it to my regular board, because I sew in 2 places and need it in both, so when I am not using it, it stands up against the wall.
I agree with others, who say, go to Lowe's or Home Depot and have them cut your board. You will never be sorry.