Just watch how the spray adhesive reacts to heat. It is very flammable when sprayed; don't know how it is after it sets up.

When I made my board larger with plywood, I was told by a quilt shop owner to drill some holes where the main ironing will be done. It seems they made some for the shop and wondered why their steam irons were always burning out. Said the steam had to get out or it does something to irons to burn them out. When I look most ironing boards do have holes in the top (before you put the padding on) Not sure if this is true, but mine works OK with the holes drilled. I put layer of insulbrite then layer of cotton batting then top fabric. Has anyone had the problem of burned out irons?

Ohhhhhh interesting thought about the holes in boards and their affect on irons.

I'll be watching this for answers.

I've been using it for some time now and everything is fine...

Not so far and bee using them for about 3 years......and no holes.
but if we make another, I will definitely put the holes to be on the safe side.

This would require you taking it apart, but I put a frame of 1" X 2" boards all the way around the outer edge of my plywood , on the underside. This gives thickness for your staples to not poke thru as well as a lot of stability for the whole board.

My ironing board is taped with strapping tape and the silver tape. It is over 5 years old and has never come apart.

I made my board out of 3/4 inch plywood, put steam holes in it, and stapled the batting and cover on. It has sure made ironing my quilt tops easier.

Why not sew a 1" hem all around your sheet, and run
elastic or strips of cotton through that to tie tightly.
Could do same with your padding, so all would be easily
removed for laundering. In other words the padding is
made same as retail ones.

Sharon Schamber has directions on her site for making a firm ironing surface from plywood, batting and canvas. I made 2, one goes on top of my ironing board and a smaller version goes next to the sewing machine.