I've started to make my own pedalboards in the style of pedal trains with my uncle, here's the current one (in the pic attached) and were making them custom sized. It's square tubular metal to keep the weight down & the them slat across with thick metal hatching across the top so that you can add both velcro & cable ties, I personally go for cable ties as they DON'T move. We're chucking them out cheap as it's just to have something to do, but then you can buy a fligh case cheap off ebay to suit.
Let me know if it's any help