This is my current lump, a rush job that was put together for our tour last year. It works well but isn't particularly easy to get around as the pedals aren't in the best places.
I'm hoping to replace it with a stepped (rather than ramped) setup. This is mspaint's finest, so the spacings are more than a little off, but this is the idea, with the signal running from top right to bottom left.
The black box top right is a patch bay. Black box bottom left is a replacement footswitch, sat as close to my delay as possible as I tend to need to switch both simultaneously. Black lump in the middle is a volume pedal between the revolver and the delay.
My plan is to make the base from 9 or 12mm plywood (keeping weight down, so now MDF etc) which is what the original junkbox is made from. The top row of pedals will be on a raised step, suitably reinforced underneath, about 5cm higher (~2"). Cable routing will take place underneath the step, and I'll be installing an N-Audio Powerbox underneath the step too, just above the volume pedal so it's equidistant between all pedals.
Historically I've used 3M lock to stick the pedals down (essentially a heavy duty velcro). Unfortunately, bonding to ply is crap since the ply splinters if you try to remove the pedals. Originally I'd planned to install something solid on top of the plywood (like stainless steel cooker splashbacks) but cutting it to size and bonding it would be a pain.
Rather, I came up with the idea of using the good ol' chain link trick:
which should work for 90% of the pedals.
What should I top the plywood off with?
i) I'd thought of carpet tiles but I'd need at least two and I don't know how to handle the join and keep it looking clean.
ii) The other option would be putting a thin sheet of melamine-faced hardboard (like you'd find inside a cupboard or drawer) which I could then spray paint bright green (fr00t!) or similar.
Once all that's done I'll need to find some PVC edging to finish it off with.
Finished it, thanks for all the input guys!