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You might be better off getting a s/h pedal train with flight case depending on that. I've seen some PT2 HCs going for around the £100 mark if they'd be big enough, though not sure how often they crop up as I'm not keeping tabs on that.
It wasn't an GORM shelf, but my first pedalboard was made from offcuts of MDF I got from the local hardware shop. I made it a two level thing with the PSU and wires tied in underneath, all fitted in a silver tool case I got from Maplins:
http://imageshack.com/a/img691/7053/nww7.jpg
http://imageshack.com/a/img39/7403/g0dg.jpg
No way would I ever use one live though.
This is what I have so far:
I have a smaller tap tempo switch incoming to replace the FS5U - couldn't be arsed to build one - and I'd be willing to lose the Boo 808 clone, and I'd be willing to go back to a Polytune Mini, if it would reduce the length requirement. This board above is a tight squeeze into 32in x 15in ... which is bigger than my Diago Showman.
Ideally I'd go smaller than that too, which is totally possible *if* I don't mount the amp footswitch into the box. But that does mean carrying around an extra bag with me; not so bad I suppose. Probably a good idea to continue to do that for spare cables and things anyway.
So if I did that, I think I'd be able to get the rest of the pedals onto a Pedaltrain 2, with some room to add one more pedal, which I may as well do since I will have a spare output on the Voodoo PP2 )
I do also have the option of getting a small 4 button midi control to control the amp, which would possibly reduce the length requirement somewhat too. But at that point, it becomes the actual pedals themselves as opposed to the controller which defines the length, and as you can see, there really isn't much in it. I don't want 3 rows to step over, two is my limit.
So I could do a combination of things. Get a Pedaltrain 2, whack my pedals on it (and figure out what to put in the gap!) and also get a smaller midi controller to act as my amp controller, thus reducing my overall floor space needs, tidying my cables up, and actually on smaller stages I'd be able to put the amp controller to my left side, hadn't thought about that before.
*sigh*
Diezel amp is still f00kin brilliant though
Can't remember the dimensions for the footswitch off the top of my head.
With the PT1 and PT2, it has round holes at the back. Does that make putting an IEC cable into your power supply tricky??
)
Gah... maybe I should go with the softcase version...