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I currently only have 20 Boyz that won't be footslogging, but if I actually manage to get a larger Ork force, I'm thinking about making simple movement trays of Plasticard and Sprues. I'll be doing them so that either 4x4, 5x5 or 6x5 25mm bases can be on it, plus one 32mm for my Boss Nob. Now, what would be the smartest design for avoiding blast weapons and maintaining coherency? I know any Large Blasts will screw me over, but still... I've seen someone do this:

O-O-O-O-O
| |
O O
| |
O-O-O-O-O

The O's are Boyz, the lines are 2 inches, enabling them to stay in coherency.

Would this work? maybe this would be a bit big...

Movement trays in 40k aren't really worth it due to terrain. You'll lose more time and get more frustrated trying to get your trays to work with existing terrain than you would just moving the guys.

Agreed, with the possible exception of Apocalypse - horde formations of 100 boys and minimal terrain? Stick those suckers on a lunch tray, for all I care. We'll be here all day, anyway!

Depending on how terrain dense your area is like rigeld said its might not be worth it

But the one iv see was a single strip of metal that the models get magged to in a line they fit into one of those organization boxes so its nice for clean up.

Probably simple lines of 5 would be ok.