I went to Michael's today and used a 40% off coupon to buy a 20' X 30" sheet of illustration board. The label states it is "Medium Textured Surface" and "Medium Weight (0.50-.060). I didn't do any math beforehand, but I was able to cut out bases for all 22 ships in the Roman Navy set - with leftover board. The bases are as follows: 14 - 5" X 3" bases for 8 Hemoilas and 6 Liburnians; 2 - 8" X 3.5" bases for 2 Triremes; 2 - 8.5" X 3.5" bases for 2 Quadremes; 2 - 9" X 3.5" bases for 2 Quinqueremes; and 2 - 9" X 4" bases for 2 Hexeres.
I also picked up a can of spray adhesive to apply backing to the larger ships. I might even use manila folder card stock for the decks of the larger ships.
Not sure what I will do to finish the bases. I have some pressed blue paper with nice texture. It is actually my wife's stash of colored paper she has when she had a box-making hobby. Or, I may use some type of blue spray paint - maybe some type of textured spray; although it is likely to be expensive.
As you can see in the photo, I just used rulers to measure the bases and cut them out with a carpet knife. Didn't take long at all. In addition to this, I also wrote a short article on Bronze Age Greek wars for the next Citadel.
Have you considered paint for your bases? I would at least try to find a shade of "craft store" paint close to your hex mat in colour . . . and try that on one of your bases (or on some scrap card stock if you fear warpage).
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I have some craft paper that may match the color of the mat.
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