OK I know what you mean, but I took the process into my hands last month. I purchases the 48x36 board cover, and pad. It requires a pc of 1/2 inch plywood that is 36x 48. I went to LOWES, and guess what, they are now selling a 1/2 sheet of plywood, that is 48 x 48 and they will make one cut, FREE, for you. I got it cut at the 36 in mark, and brought home both pcs of wood in my car, I borrowed a staple gun (with compressor) I adjusted the pad and fabric, tucked and stapled per the instructions, and now I have a wonderful ironing board.
Its not that hard to do for these guys, it just seems that they like to make us wait for their help, not me, I just get in there and do it! Oh by the way, I had called Lowes, and the lady told me of the 1/23 sheet of plywood, but the guys in the lumber didnt know about it, but I persisited and he looked around and found that someone just "slipped this in on him". Good luck, BB