I've seen a few plans floating around the internet showing various solutions, but I didn't like the way they attached the new bigger top to the old ironing board. Velcro, clips, grips…too bulky, too unsightly, and difficult to store during those rare moments the pointy end of the original ironing board is actually needed for normal laundry.
My wife's ironing board is a fairly new model, so the top is made from plastic…that ruled out the bulky clamping approaches. Using velcro just didn't seem sturdy enough to keep an oversized board in place.
Fortunately, when I peeled back the cover on her ironing board to see what might work, I discovered the plastic top had a great pattern of holes…and a simple solution was inspired! You can see her ironing board, minus its original cover, standing next to the new top in the first picture. The second picture shows the new top in use.
I've made three of these at the TechShop in San Jose. For more info on TechShop, see their website at: http://www.techshop.ws
Step 1: Materials & Tools
- 5/8" plywood (you may have to settle for 19/32", just call it 5/8", it's close enough)
- 4 @ 10-24 threaded inserts (Woodcraft item #12K10, ~$4 for a pack of 10)
- 4 @ 10-24 miniature knobs with 1/2" studs (Woodcraft item #27R11, ~$4 for 2 packs of 2)
- 4 @ 1/4" washers
- Heat-resistant ironing board cover material (Bo-Nash.com's "Extra Large" with foam pad)
- tape or Scotch brand Super 77 Spray Adhesive
- Ironing board that desperately needs a bigger top
- Drill w/ 3/8" diameter bit
- Tape measure
- Panel saw or table saw
- Jig saw
- Random-orbit sander w/ fine and very-fine sand paper
- Slotted/standard screwdriver or 10-24 T-wrench (Woodcraft item #12K15, ~$5)
- Silver Sharpie (or similar permanent marker)
- Dust mask (use while sanding)
- Tarp (or old newspaper if you can still find that stuff)
- Razor knife (box cutter)
- Staple gun (not the stapler from your desk at work!)