Missouri Star Quilt Co did a tutorial on making a 34" by 36" (approx) size ironing surface. The wood they suggested was 1/4" floor underlayment material because water does not effect it. It is also light and can be carried to a class or retreat. They took an old towel and doubled it to lay on the board and covered it (made it like a pillow case, can take it off and wash easily) in regular fabric. I am like BellaBoo, I like a firmer board. I have always been told that is best for applique, too. The floor underlayment material can be found at any lumber co., and you could make any size you want.