I have a homemade ironing board that sits on top of a metal rolling medical cart. I love it. It is essentially a rectangle with rounded edges of 1/2" thick particle board (wood chips, not foam) Then there are two layers of cotton batting, ironing board fabric, cotton batting again, then muslin on top. The entire sandwich is folded around to the back and stapled with heavy staples. I have recovered it several times by just adding more fabric to the top. A few years ago, people were making ironing boards out of wooden tv trays. I'm sure the directions are out there somewhere.