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DIY Rolling Ironing Board Station - Organize Your Space

In the spirit of the new year, I have a DIY project that will help organize your sewing space. I researched many ironing boards and ironing board stations DIY style and ready made. I made this one by getting inspiration from several pictures on the internet. I made alterations to make it a rolling cart with storage. Once the supplies are purchased for the project, it was pretty easy to make and will only take a couple of hours of your time to build it. If you have a handy helper, it's even better and moves along quickly. I enlisted the help of my brother in law, but asking one of the home do it stores to cut a straight piece of wood for your project works just as well. It is versatile and sturdy. I designed it so that it would be counter height without having to bend while ironing. I have included all of the links below to get the supplies that you need.

Dimensions: 36"height x 16" deep x 48" long (Length of Board) and a 30" long base shelf unit (The Kallax shelf dimensions: 30"x30" square and 16"wide)

Material's List:

  • Plywood 3/4" thick board cut 16"wide x 48"long (Home Depot) (Use the same board for the Castors Platform)

  • Two - 3/4" thick plywood 6"wide x 15 1/4" long for the Castor's Platform (Home Depot)

  • Three - 3/4"thick x 1 1/2"wide x 15"long wood or synthetic wood strips used for spacers from the ironing board to base (Home Depot)

  • Gorilla Heavy Duty Adhesive: or equivalent adhesive (Home Depot)

  • 4 - 3"diameter castors with screws (Amazon)

  • Ikea Kallax Shelf :

  • 26" x 58" Cotton batting (Additional layer of foam under the cotton batting can be used but is not necessary. I used it for more padding.) I used larger pieces and cut them down to size (Shown in the pictures below.)

  • Ironing board heat sensitive covering 26" x 58"(Shown in the pictures below.)

  • 26" x 58" of 100% cotton fabric

  • String to make a drawstring for cotton cover if not stapling the cotton cover directly to the board.

  • Automatic drill with drill bits or screw driver

  • Staple gun and staples

  • Hammer and nails (Optional but not required). The nails need to be at least 2" long and thin, similar to finishing nails.

Step 1:

Assemble the Ikea Kallax shelf. Ikea directions are basic but the shelf was pretty easy to put together. My brother in law is the hero here by putting the self together. I have put these together before as well and they go together quickly.

Step 2:

Cut the lumber. Having one of your local home do it stores to cut the lumber works perfectly. If it is a straight cut, they will do it for free. I bought a 24" x 48" board and used it for the top and castor platforms.

  • Cut the ironing board top: 16" wide x 48" long

  • Cut the castor platforms: 15 1/4" wide x 6" long

  • Cut three 3/4" thick x 1 1/2" wide x 15" long strips of wood for the spacers

Step 3:

Attach the spacers to one side of the Ikea Kallax shelf (The shelf is square so any side will do.). Attach the spacers using the construction adhesive. Apply it generously but not too much so that it does not squeeze out the bottom. Optional: Use one nail at each end of the spacer strip to secure the strip to the shelf. The construction adhesive secures the shelf to the strips very well so nails may not be needed. The shelf is hollow so be careful when using nails. I suggest using a thinner diameter nail.

Apply each spacing strip equidistant apart from one another (One on each end and one in the center.). Once applied, allow the construction adhesive to dry.

Step 4:

While the construction adhesive is drying, cut two or three layers of batting (I used two layers of batting and foam) and an ironing board heat resistant fabric. Cut each layer of batting (and foam if using foam) and the ironing board heat resistant fabric to 26" x 58" each (I used larger pieces of fabric then cut them down to size when fitting the board). Lay the ironing board fabric right side down on the floor (wrong side facing up). Lay the batting and foam on top of it. The foam should be closet to the board. Put the ironing board on it.

Using a staple gun, pull one side of all three layers over to the bottom side of the board and staple it. Go to the other side and pull the three layers tight and staple again. Continue to do this around the whole board until it is smooth and fairly tight on the top side of the board. Cut any excess fabric and batting away from the board on the bottom side.

Step 5:

At this time, you can choose to staple a cotton cover over the board or make a removable cover. I ended up making a removable cover. The dimensions will be the same for the cover. Cut the cover 26" x 58". Follow Rob Appell's video below if you prefer to make a removable ironing board cover.

Rob Appell with Michael Miller fabrics has a great tutorial so I included the Youtube video link to watch it. The same principles apply with a square cover as well as a pointed cover at one end.

The cover is now ready for the board. Put the ironing board cover aside for now.

Step 6:

Take the Kallax shelf and place the side on the floor that has this wooden strips glued to it. Now, the side facing up opposite to the side with the wooden strips will be where the castors are placed.

Take the two 3/4" thick x 6" wide x 15 1/4" long wood castor platforms and glue them to each end of the Kallax shelf using the wood glue adhesive. Optional: Add nails to the ends of each board for extra security and strength (Remember that the Kallax shelf is hollow). Allow the glue to set and dry.

Step 7:

Place a castor on each end of each of the boards (Two castors per board/platform.). If needed, mark and pre-drill pilot holes. Screw in the castors on all four sides. Turn over the cart onto the castors.

Step 8:

Add construction adhesive to the three spacing strips on top of the cart/shelf. Place the ironing board on top of the spacing strips

as shown to allow it to lean over the edge to have a free arm or as you would prefer. Allow it to dry and set.

Step 9:

Put the ironing board cover on, cinch it down around the corners and tie it in place. All done. You now have a rolling ironing board station with storage. More organization tips coming this month. Thanks for reading my blog.

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