I made my current ironing board 9 years ago. The outer/working surface is/was good quality white fabric. Guess I haven't damaged it enough to replace - yet. Really not looking forward to doing it as I'll have to remove a gazillion staples from my staple gun.

I buy twill yardage, the heavy muslin kind you find in the upholstery dept. I pull it taught over a large piece of plywood that I use as my ironing board, screwed to an ironing board base. It gets brown in spots and has fabric dye in spots but who cares. When it gets a hole in it, I'll start all over. On mine, I draw squares of various sizes with a sharpie to use as a template for ironing HSTs without stretching them out of shape. So, I want to get a lifetime of use out of my cover and won't replace it till I have to. If you pull your cover off your ironing board, you will find it likely has all sorts of holes you can use to screw a piece of wood down from the underside. The lumber yard will cut you a piece of plywood any size you want and you can cover that with batting and a layer of heavy duty fabric. Great surface for quilters and it still folds up. I can even iron a shirt on mine if I have to!

I have a large board as well. But rather than removing the fabric each time it gets dirty, stained or ripped, I simply add a clean fabric over what's already there. Then every so often (years), I pull all layers off and start over. So, it's a little like Princess & the Pea! lol