Here is a blog post I did last year when I recovered mine. It shows the size and materials used.

bbquiltmaker.blogspot.com/2016/07/before-and-after.html

Ok, here is my 2 cents on your ironing surface. I make draperies,etc for 40 years. I have a table that is 4' x 10', yep its BIG and comes in very handy for quilting. I go to the lumber yard and get a sheet of celotex, or fiber board and they will cut it for you. Get the 1/2" thick. Cover it with a muslin or cheap sheet from the store and staple it on the back. Now you will have a sturdy board and can use pins and iron on it. You can just sit the fiber board on top of your plywood or staple the fabric to the wood. DO NOT get foam core, it will melt. I hope this helps. I have only had to replace the fiber board 3 times in 40 years and it gets used.

Sharon in Colorado.

I am going to use a short bookcase that I will put wheels on. That way I have storage for ironing supplies, etc. I am going to put a piece of plywood on the bookcase but I am not sure what would make a good padding and cover for the ironing board surface.

Personally I use half an old wool blanket on my sewing table, although I have to admit that after 17 years the surface of the table is showing signs of wear from the steaming that I have done. But it does give a lovely big area for pressing (when not covered with projects etc.)

Has anyone made a large rectangular ironing board? I want to be able to iron a full width of fabric on it and leave my iron on it as well. Any suggestions? Thank you.