Wow! So many good tips in this post!
My husband built an ironing board for me just recently, with things we had "on hand".
I wanted to have something that I could move around easily and I could put away - so a top I could remove that wouldn't be too heavy. I had this shelf storage on wheels that I wanted to use for this.
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I also wanted a top that would be big enough for the width of the fabric and more. I knew that there could be an area where it could tip or that the top could slide off the shelf. We had a board of "MDF" 3/8 " thick, and 64" X 24" - a real dream compared to my old ironing board (that you can see on the picture). Since this could bend easily, he made a frame around it with wood stud (looking for a better word - a frame made with 1-1/2" x 1" wood). He also put a frame to "surround" the top of the shelf, so the board would not slide.
This is what it looks like underneath:
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I put 2 layers of cotton batting, with a layer of that silvery fabric (tefflon?). Can't pin anything though... but now, I can iron more that 12 inches at a time! It's not as nice looking as I wanted it (the top), but it works...
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Andrée