Build a Big Board Ironing Station with IKEA Kallax Storage

​Every once in a while I like to share projects that make quilting easier—not just designing quilts.

This week I'm taking a short break from my usual Electric Quilt 8 tutorials to share a project I've been working on in my quilting studio.

As I've been settling into my new quilting space, I've been looking for ways to make it more efficient. My latest improvement was building a large, movable ironing station with plenty of storage underneath.

After researching lots of options (and experimenting with a few ideas that didn't work!), I finally came up with a solution I'm really happy with. If you've been thinking about adding a Big Board to your sewing room, I hope my experience helps make your project a little easier.

​I'll even share the EQ layout I created to position the Velcro strips perfectly.

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Building the Base

Most Big Boards are designed to sit on top of a standard ironing board. I wanted something sturdier that also provided additional storage, so I chose an IKEA Kallax shelving unit with the metal underframe.

I selected the 4 x 2 Kallax. It measures approximately 57⅞" x 37" (including the underframe) and is available in either white or black.

Rather than making the 50-mile drive to IKEA and navigating the maze of the store, I ordered it online. Delivery was only $19, which was well worth avoiding the trip—and I didn't have to wrestle a large flat-pack into my car.
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Assembly was surprisingly straightforward. The instructions were clear, and I was able to put everything together by myself. If you're comfortable assembling basic furniture, you shouldn't have any trouble with this project.

Kallax Unit with Base

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Adding Casters

Adding wheels turned out to be the most challenging part of the project.

Because I wasn't comfortable drilling into the shelving unit, I spent quite a bit of time researching alternatives—including several conversations with Google's AI—to find a no-drill solution.

After a number of failed ideas, I found one that works beautifully.

I purchased a set of 2-inch side-mounted L-shaped swivel casters with brakes. Their mounting plate fits nicely against the metal legs of the Kallax underframe.

To attach them without drilling, I used large stainless steel hose clamps.

Each caster is secured with two hose clamps—one wasn't enough, as the caster shifted slightly when rolling the unit. Tightening both clamps firmly allows the metal to grip both the frame and the caster plate securely.

​If you decide to build one yourself, I definitely recommend using two clamps per caster.

Side Mounted Casters

Large Hose Clamps

Caster Placement on Underframe

Casters attached to Frame

Completed Kallax Base with Casters

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Other Base Options

If you're comfortable using a drill, another option would be to purchase the Kallax without the underframe.

You could attach a sheet of plywood to the bottom of the shelving unit and mount traditional plate casters directly to the plywood.

​Or, if your ironing station won't need to move often, simply skip the wheels altogether and use furniture sliders whenever you need to reposition it.

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Building the Big Board

Choosing the Size

​I found a 22" x 60" wool pressing mat on Amazon and decided to make my Big Board the same size.

One of the advantages of a wool pressing mat is that it reflects heat back into the fabric, effectively pressing both sides at once. The dense surface also grips fabric to reduce stretching while helping produce beautifully crisp seams.

​Unfortunately, I'm allergic to lanolin. Simply touching wool gives me a significant rash.
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My solution was to completely cover the wool mat with a heavy canvas layer. I still receive all the benefits of pressing on wool without ever touching the wool itself.

Cutting the Plywood

Home Depot will cut plywood to your requested dimensions when you purchase it.

I bought a standard 4' x 8' sheet and had it cut to 22" x 60".

Although I had to purchase the entire sheet, I now have enough leftover plywood to make additional travel pressing boards—or perhaps share with a quilting friend who wants to build one too.

I actually purchased a slightly nicer grade of plywood, but after completing the project I think the least expensive option would have worked just as well.

​On the back of the plywood, draw guide lines showing where the Kallax unit will sit.

These guide lines make positioning the Velcro much easier later.            

Back of Plywood with Layout Lines

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Adding the Heat-Resistant Layer

Cut the scorch-resistant fabric approximately 25" x 66".

Center it over the plywood and clamp it into position.

Working one side at a time:

• Fold the raw edge under.
• Pull the fabric snug.
• Staple it to the plywood.
• Create simple folded corners, similar to wrapping the corners on quilt binding.

​This layer protects the plywood from heat while creating a smooth base.

Scorch Resistant Fabric Stapled to Plywood

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Adding the Wool Mat and Canvas Cover

Turn the board right side up and place the wool pressing mat on top.

Cut a piece of canvas approximately 36" x 66" and center it over the mat.

Clamp everything together before flipping the board over.

Working one side at a time:

• Pull the canvas tightly.
• Fold the raw edges under.
• Keep the top surface smooth.
• Staple the folded edge to the plywood.

​The canvas gives the board a clean, durable surface while completely covering the wool mat.

Wool Mat Positioned on Board

Canvas Pulled Tight and Stapled

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Attaching the Board to the Base

To keep the Big Board secure—but still removable—I used heavy-duty adhesive Velcro.

Before attaching anything, I used EQ to create a spacing diagram so all of the Velcro strips lined up perfectly with the shelving unit below.

Attach the matching Velcro strips to both the underside of the board and the top of the Kallax unit.

When assembling everything, line up one edge first and then lower the board into place.

The Velcro holds extremely well, yet the top can still be removed whenever I want to transport it to a quilting retreat.

EQ Velcro Placement Diagram

Velcro on Big Board

Velcro on Kallax Unit

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The Finished Ironing Station

I'm thrilled with how this project turned out.

As a bonus, I had enough leftover canvas to recover my portable pressing pad, which was definitely showing its age.

​Now I have:

• A generous 22" x 60" pressing surface
• Eight storage cubbies underneath
• Locking wheels for easy mobility
• A removable Big Board for travel or retreats

Finished Ironing Station

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Project Cost

​Here's what I spent:

Since the total includes both the wool pressing mat and the purchase of an electric staple gun, your cost could easily be lower if you already own those items.
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For comparison, commercial Big Boards without a base can cost around $160, and a wool pressing mat of this size is often another $130. My DIY version came in at a comparable price while giving me storage, mobility, and the flexibility to remove the top whenever I need it.

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Product Links

Below are links to the products I used while building my ironing station. If you purchase through my Amazon affiliate links, I receive a small commission at no additional cost to you. Thank you for supporting On Point Quilter!

• IKEA Kallax Shelving Unit with Underframe
• 2" Side-Mounted Swivel Casters
• Large Stainless Steel Hose Clamps
• Scorch-Resistant Fabric
• 22" x 60" Wool Pressing Mat
• Heavy-Duty Velcro Tape
• Bielmeier Electric Staple Gun

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Have you built your own ironing station?
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I'd love to hear what worked for you—or any improvements you've made to your sewing space. Share your ideas in the comments below!

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