About a year ago, friends and I put together a bunch of copies of an out-of-print board game. We built a mat-board board with a color-printed playfield glued on, made mat-board pieces, got wooden men from the craft store and painted them. A lot of work, but it was a lot of fun, and the results were quite nice. Some recommendations:

For my latest game, an original design, I just needed a Pinochle deck, some Poker chips, and the rules. Much easier to build. Recommendations on game design: