[header] How to make an ironing board cover from scratch [title] If your foam underneath is ripped or scruffy, you should replace that as well. [step] One thing that you can try is upholstery wadding underneath. [title] Untie the cord from underneath the existing cover (it is probably wrapped around a plastic toggle. 
[step] If it is, good, you have half of your materials already). Pull all the string out, and stretch the cover out flat.