I too always make my ironing board covers. I make the pattern from the ironing board top to get the correct size and shape. You can make a pattern by turning the ironing board upside down on a sheet of paper, trace around the shape and cut out. I like to quilt my fabric, using the print plus pre quilted calico (prewashed for shrinkage). Pin together on the quilted calico side and proceed to quilt on every second line of the pre quilted pattern. when quilted lay out on the cutting table, pin on pattern, measure 2 1/2 to 3 inches around. cut a casing 2 - 2 1/2 inches wide press in half, sew a hem to the starting end and pin and sew around the shape, starting at the top end. Hem the end where the casing comes to meet. Sew and overlock, thread elastic through the casing and fit to ironing board. You will have a very well fitting ironing board cover. Some fabric stores sell the thicker felt that can be used to replace any old or worn felting under the cover. I even have an ironing board cover that I take when we travel as I find there is nothing worse that the ill fitting worn ironing board covers at some Motels and I do like to press our clothing before it is worn.