devinsounds like you're going to be making a plywood board then..when i made plywood boards i'd just laminate 3 sheets of 3mm plywood togehter and put it under a few hundred pounds of bricks with 2x4's on the ends and let it cure/set.
i'd suggest drawing your outline on the board before laminating.
now sand/router the edges and install the t-nuts, then seal the board with a few coats of varnish.
holes for fins are nice too...draw those out when you make the outline of the board.
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