My husband and I recently made a large board to cover my regular ironing board. I just used a polyester batting. For the cover I used the silver heat reflecting fabric. Sorry I can't remember what it is called. The board itself is 1/2" thick particle board. At least I think that's what it's called. We purchased it at Lowes and it was what they recommended. It's 25 by 65 and I just love it! I wonder how I ever lived without it. If I'm using starch, I throw a large piece of muslin over it. Much easier to wash that since the cover is stapled on. I think the total cost was about $35 and I have a second board to use plus a large leftover piece.