Why are pedalboards so expensive? Well, when I built my pedalboard I spent about $30 on the hardware. I had extra plywood and carpet laying around, so I didn't have to buy that, nor do I know how much it would've cost me. Let's assume that you'd spend a bare minimum of $25 on that stuff. Also, industrial Velcro (used to stick pedals to the carpet) is expensive. I think I paid like $13 for 8 feet of 2 inch. So If made these assumptions, we're looking at almost $70 in materials. Add to that labor, marketting, middle-man mark ups, etc. and you can see why pedalboards are so freaking expensive. You can certainly make one cheaper than I did though.
Current rig: Les Paul Classic (Texas BBQ set and fine tuning tailpiece) or Les Paul Studio > SD Pickup Booster > PT-100 > Original Cry Baby > MXR Dynacomp > TS9DX > MT-2 > CH-1 > Stereo Pulsar > NYC Small Stone > Deluxe Memory Man > PDS-1002 > Verbzilla > Ampeg Reverberocket (R12R)