I've been wanting an oversized ironing board for my quilting. DH recently made this one for me. It is a 22" x 62" plywood board covered with one layer of leftover scraps of a cotton batt (warm & natural) covered by a heavier cotton pillow ticking fabric. I LOVE IT! I does take up quite a bit of space in my small, slightly messy (snicker), basement quilting corner, but it works. (See my little yellow space heater? It's my best friend down there in the winter.)
Here's the underside. The board fits over my existing ironing board. The furring strips keep the long board secure.