Make a custom ironing board for your sewing workshop
If you sew seriously (whether it's for cosplay, LARP, or just because sewing is your passion) you've probably already had this love-hate relationship with your ironing board.
Too small. Or on the contrary, huge and cumbersome. Not stable. Tips over when you iron with a bit of enthusiasm...
I can't be the only one who hates standard ironing boards, right?
The truth is, a standard ironing board is designed to iron shirts every now and then. It's not designed for someone who's ironing yards of fabric and pressing seam allowances throughout a massive cosplay or LARP costume project.
So, a while back, I decided to build myself a custom one. And I'm really happy with that decision. It's not a complicated project. It doesn't take long to make. And it's not expensive. Plus, you can adapt it to your space.
If you, too, want an ironing board that's truly suited to your needs and your space, let me show you how I made mine.
Fixed board or portable board?
Before you start, you need to pick your setup based on your sewing space.
The fixed board
This is what I made for my workshop. I screwed it directly onto a cart, and it stays there permanently. This is the best option if:
- You have a dedicated sewing space (a workshop, a corner of a room) that you don't put away after every session.
- You sew often and don't want to waste time setting up and putting away your board every time.
- You have access to a sturdy piece of furniture that will become your ironing corner (a cart, a counter, etc.).
The portable board
This is the version you set up on a counter or table when you're sewing, and store behind a piece of furniture when you're done. This is the best option if:
- You sew in your dining room (and have to put everything away before dinner).
- You don't have a fixed space for a permanent sewing setup.
- You need something you can move from one room to another.
Either way, the building process is exactly the same. The only difference is size. I'd recommend keeping a portable board a bit smaller (to reduce weight and make it easier to carry). The fixed board can be a bit bigger since you won't be moving it around much.
What you'll need
Materials
- A ½" OSB board (or ¼" if you want something lighter) in the dimensions of your choice (more on that just below).
This is a sturdy type of board, it won't warp with heat and humidity, and it's easy to find at the hardware store. I chose ½" to be sure it would hold up well, but ¼" does the job too if you want something lighter for a portable board.
- Aluminum foil tape (the kind used for ventilation ducts).
It creates a moisture barrier between the steam from your iron and the wood board — you really don't want mold getting into your board. Plus, it's heat-resistant. No need to worry about high temperatures.
- 3 layers of cotton batting (quilt batting) large enough to overhang the board by at least 2" all the way around.
There are different options here: Kodel, upholstery foam, any kind of batting. Personally, I really prefer cotton batting because it gives just the right amount of give without being too soft and fluffy. Plus, it can handle very high temperatures without any issue. I'm really not worried about anything burning on my board.
- A piece of cotton canvas the same size as the batting.
Cotton is essential here because your fabric will be in direct contact with your iron. You want something that can handle even the highest temperatures. You could also go with a Teflon fabric cover if you want something even more resistant... but personally, I know myself, I'll end up staining my board. I'd rather have something I can replace without much hassle.
- ½" staples (or ¼" if you go with a thinner board) *not your little desk stapler, the construction kind.
Tools
- A saw (or ask the hardware store to cut the board to size — most will do it on-site)
- A construction staple gun
- Scissors
What size should you pick?
It really depends on your space and what you sew.
For a fixed board: Aim for something that covers your work surface well. Mine is 24" x 36". That's just a bit bigger than the cart it's screwed onto, and I really like that. You could go longer if you have the space (looking back, I realize I would have liked mine a bit longer, personally...).
For a portable board: Think practical. You need to be able to lift it, carry it, and store it without too much effort. Think about your work space (even if it's always temporary), but also your storage space (behind a piece of furniture? in a closet?).
Either way, I'd recommend something deeper than standard ironing boards. You'll appreciate the upgrade, I promise.
The steps
Step 1 — Aluminum foil tape
Cover the top of your board entirely with the aluminum tape. Make sure there are no bubbles and that the seams overlap well to form a real barrier.
Step 2 — Cotton batting
Lay your 3 layers of cotton batting on the floor. Place your board right in the center, aluminum side down (against the batting). Make sure the batting overhangs by at least 2" all the way around.
Fold the batting layers over and staple them to the underside of the board. I'd recommend starting at the middle of each side, then working your way toward the corners. This helps keep the fabric nice and taut. Leave the corners unstapled for now.
Step 3 — Trim the excess
Trim the excess batting if needed so the edges are nice and clean.
Step 4 — Fold the corners
The corners are the trickiest part. Take your time folding them neatly (like wrapping a gift, but sturdier). Add a few staples to hold everything firmly in place.
Step 5 — Finish the edges
Finish up by adding staples all the way around to make sure the batting is well secured everywhere.
Step 6 — Cotton canvas
Repeat the exact same process with your cotton canvas over the batting. This is the layer your iron will be touching directly, so make sure it's nice and taut and well secured all the way around.
And there you go — your custom ironing board is ready!
Taking it further
If you have a fixed board, you can screw it directly to your furniture from underneath so it doesn't move at all. That said, if you place it on a stable surface, it's not going to wander off on its own either (it's not absolutely necessary).
If you go with a portable board, you can cover the underside of the board for a cleaner finish, if you'd like. You could also add a big hook to hang your board in a closet (for super practical storage).
If this article made you want to rethink your whole sewing setup, I'd also invite you to read my article on choosing a good iron (including how I built my rack for a gravity-feed iron) and my guide to reorganizing your workshop.
And for other workshop essentials, check out my article on my 10 favorite sewing tools.
And once your ironing corner is all set and ready to go, my patterns are waiting for you:
And if you want to stay in the loop on new products, promos, and new articles to help you with your creative projects, join The Harbour!
In the meantime,
Happy sewing! Happy crafting! 🤓✂🐙