So, a few local 30k players (well, the only local 30k players...FOR NOW) and I were wanting to start a narrative campaign - the idea would be to start with smaller ZM games and scale up so we have a good handle on our armies at every points level. I have a somewhat-decent stand in for a ZM board currently, but I'd like to actually just make my own because it is a huge pain in the ass to put together the current one each time we play. No way in hell am I paying
FW prices for their board (just their minis

), so this seems to be the best course of action. I was thinking of approaching it as such...
Plastic 12"x12" tiles for the base - just plain tiles; if I can find one with 1" squares beveled in, I'd be a happy camper, but its by no means a necessity.
Either plastic or laser
MDF walls for corridors, affixed to the tile for the sake of permanence. No preference on actual aesthetic, as it will be heavily weathered and converted.
Any ideas on where to get this stuff? I've been scouring
MDF las cutters but nobody seems to have something quite right for what I'm trying to accomplish. I can't seem to find plain plastic tiles either - all just lineolum (too flimsy), terracotta (too breakable), or some other undesirable substance..
Has anyone made their own board before? Seen any good tutorials? Anyone know where to find this stuff?
Cheers!