Designing stuff is fun so here's an idea for a pedal board design.
Start with wood sides like a Moog synth, I think 100% wood pedalboard will look great but might get heavy so I'm going wood sides only with this idea.
The wood sides should be angled, 2" high at the front and 5" high at the back. Holding the two sides is a U shaped sheet of aluminum or sheet metal forming the front, floor and back of the lower pedal chamber. Hopefully the front is just deep enough so that you can slide a couple of power supplies right to the front of the lower chamber leaving room at the back for a row of regular height pedals. (This is where you hide all your Boss stuff

).
Basic shape:

The wood sides would be routed for power input jack and various 1/4" jacks. I like to stand on stage right so I'd have all my connections, guitar in, power in, amps out, located on the right hand side.
The top would be slotted with slots wide enough to pass a patch cable through at intervals that match the width of a roll of velcro.
If everything worked out you should be able to hold as many pedals as a PedalTrain Pro but in the footprint of a board that will fit into one of these smaller Mono cases:
