I used several types of pedal boards (self-made using stainless steel or wood, custom cases, ...) and all of them had the same problem, that the weight was quite high and placing the holes for mounting was not very comfortable.
Finally I found a solution that perfectly fits my needs: "Dibond" is a leightweight, robust, easy to work with, inexpensive and nice looking material:
http://graphicdisplayusa.com/products/dibond/
Drilling holes is very easy and in most cases no additional "mounting kits" are needed, I used the original screws of the mounted devices.
On the bottom I mounted four large rubber feet by using glue for shoe soles (sticks like hell ;)). The rubber feet are available at any DIY market for little money.
I ordered my Dibond (3 mm thickness) here:
http://www.plattenzuschnitt24.de/Alu-Dibond/Dibond-Schwarz/
The final result looks like this:
[Blocked Image: http://up.picr.de/21611953df.jpg]