I buy 1-1/2 yards of the silver tone fabric from Joann's which will make 3 ironing board covers. I use the old cover for a pattern but I make it shorter at the large end by about 4", then I sew a piece on the narrow edge so it will stay hooked over the end. I turn up the edges all way around and stitch, then I use safety pins and pin it to the old thick pad in this hem, it holds better and won't pull the pins through the fabric. When it gets nasty I toss it and make a new one. By cutting it shorter it is enough for 3 covers. Works for me.
I like everyones ideas. Thanks