Ok, so I have build a couple of Gorm boards now, so I thought I would add some pics of the process. Many kudos to the OP and the guys who had such a brilliant idea!
base gorm:
I took 2 of the boards and removed them. When you move the outside board to the edge and then re-center the middle board, you end up with slots large enough for cable heads. No drilling!
Since the nails used to hold it together don't especially enjoy being removed and then put back I reinforced everything with wood screws. The wood is soft enough that you can force it to countersink itself.
Don't worry too much about damaging the wood - it will mostly end up being covered by paint and velcro.
Primed, sanded and ready to paint:
Painted and with hardware for final assembly:
I used threaded inserts to mount the legs to the back of the board. I have an old keyboard case that will fit this board perfectly, so I have to have removable legs. I found the inserts, "legs", and rubber feet at Home depot for < $5. The most expensive part of this project is the velcro, but 1 package had enough velcro to complete 1 large and 1 small Gorm board. Another thing: Using the rubber ends on the legs like that means that you can't crack the wood when screwing the legs in because when you hit bottom, the knob will turn, but the screw won't.
From below:
Completed Gorm:
Hope this helps! What a great way to save some dough and still end up with a sturdy, fully-functional pedalboard!
Pics of the board with pedals will be up shortly in the "show your board" thread.
