There are lots of options when it comes to pedal boards. Doing a simple image search on Google yields plenty of options; from high-end pricey boutique designs, to the famous Ikea Gorm DIY boards, to simple velcro and plywood.
Here is my attempt at making something that would work for me.
Step 1: A Compound Bow Case
So after lots of research and a few different designs on paper, I decided to go with a pre-made compound bow case ($40)
My first step was to do some small alterations.
Step 2: Start Adapting
I used the supplied foam insert as a stencil for making a solid bottom using sub-flooring. I then removed some of the "clips" and unnecessary pieces from the case and filled in the dips in the shell to ensure the support floor would be flat against the bottom of the case.
Step 3: I've Got the Power!
I used some surface-mount receptacles on either side to allow for 2 additional items to be plugged in to my case, (i.e. amps, etc)
I also mounted a fused toggle switch under the handle.
Step 4: The Insert
Next step was to make my insert. I used 1x2 and created a 3-tier system. (each 3/4 inch higher than the last) This would make the 2nd and 3rd row of pedals more accessible. I dismantled and cleaned up some old bike chain to use for mounting the pedals to the board. Where the links wouldn't work I used strapping.
Step 5: Trial Fit
Now that the insert was "done" i did a trial run inside the case to ensure that everything still fit and then i did some final adjustments with pedal position and screwed them in.
I removed them again before I painted it black and added a powerbar under tier 3.
Step 6: Wires... Wires... Wires!!!
Next I took the insert back out and ran the patch-chords in my desired order of signal in my effects chain. The power was next. I connected the power using daisy chains to a 2 amp 9v adapter I purchased online to ensure i had all the power i needed.
I ran a test on the chain to ensure everything was working properly then I used cable ties and strapping to keep all the wires out of the way.
Step 7: Re-insert the Insert
Putting the Pedals back in the case was interesting and challenging. Lots of re-positioning with the cables to ensure the board fit tight to the bottom and nothing would get damaged.
(you'll notice a hub in the bottom of the case... that was needed to make the insert completely removable without multiple wires to be disconnected.)
Step 8: Screw It
I secured the insert using screws through the case all the way around..
I customized some loose pin hinges to enable them to come apart without removing the pin. and mounted them replacing the original plastic molded hinges.
Step 9: What Use Is a Pedal Board If You Don't Have Feet?
A slipping pedal board is not fun!!! Rubber feet do wonders.
Also had to dress up my little girl with some bling (screws and strapping)
Step 10: Fin!