Scott, the tale of the muffin tin board for the 65mm Angulon is my page. Apparently that adventure had the effect of circumscribing my thinking about the problem, since I was considering the only way to make a lensboard for a Graphic was to use the original extruded design. Your example got my thinking moving again outside the box. Working with wood and the possibility of using a flat lensboard opens up some new possibilities. So now I am going to offend the sensibilities of the classic audience and the precision audience.
I've used .64 and .90 mil aluminum stock for flat lens boards. Whichever is the right thickness for the SG mount, that could make the basis for a strong front apron. A tub wall could be made of thin strips of walnut or cherry, sized so that its external dimensions were slightly smaller than the CG's "well" creating a bit of a light trap as well as a tub. Even with butt joints, it should be possible to make a lighttight tub. The lens board could be aluminum. .64 mil would be strong enough and it is easy to make lens openings with ordinary hole saws and a basic drill press. Some combination of adhesives and small wood screws could attach the wood frame to the aluminum parts. Even painted black to hide the dissimilar materials, this would be the ugly sibling of your cherry board, but for those of us who have restored Graflex models, this marriage of metal and wood seems natural enough.
I asked Bruce Wehman about the recessed board shown on his page that describes creating a SG back with movements. He said he started with a stock board, then made the tub from brass sheet stock. I think he said that he had a 65mm Super Angulon mounted and the tub looks to be more than an inch deep, enough that he said he had to make some control extensions.
http://www.wehmancamera.com/modification.htm
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