I made a big retangular ironing board using 3/4" plywood. They cut it to the exact size I needed (many thanks to the lumber yard) and put cotton batting around it and then used 100% cotton to cover it. I used a staple gun on the back to hold the material in place. I've had to change the material once, which was no big problem. I now have it sitting on a long dresser (one that usually has a mirror on it) and it needs some boards on either side to stop it from moving. Before it was on my ironing board and didn't move. But putting it on my dresser, I have 6 drawers to put my fabric and things in. Got the idea here on the board.