For ease, nothing beats the iron-on transfer method.  You can use glossy
ink jet paper, laser print the layout on it and iron it onto the
copper-clad.  It takes a bit of finesse but once you figure it out you
can get pretty fine traces on there consistantly.

The light-sensitive transfer methods work too, but the boards are more
expensive...

As far as drilling holes?  Use a layout program that will put a hole in
the pad for you, then your drill just slips in and you can't possibly
make a mistake without trying.  I use a Dremel with tiny bits, but a
normal drill would work too.

For layout software, I highly recommend Eagle (www.cadsoft.de).  Their
trial version is fully featured, doesn't expire, or nag.  Just has a
size and quantity limit for boards, which is almost always big enough
for hobby projects.  It has an autorouter, etc...  Very nice for what it
is.  Learning curve isn't sharp at all either.

nick@veys.com | www.veys.com/nick

> -----Original Message-----
> From: pic microcontroller discussion list
> [mailto:PICLIST@MITVMA.MIT.EDU] On Behalf Of Pic Dude
> Sent: Wednesday, March 06, 2002 11:48 AM
> To: PICLIST@MITVMA.MIT.EDU
> Subject: [EE]: Making PCBs...
>
>
> Couldn't find a good answer to this in the archives or web, so...
>
> Trying to figure out how to make professional-quality PCB's
> at home. These will be one-offs, so I'm avoiding the option
> of using a PCB service. But I would like them to look professional.
>
> The Ferric Chloride etch method is great, and I have all the
> stuff for that, but I always have 2 problems: drilling holes
> neatly, and laying out the pattern onto the board.
>
> For the holes, I've circumvented the problem by
> surface-mounting my components.  It takes up a little more
> space, but I can mount one circuit on top, and another on the
> back of the PCB, so I can actually save space.  For more
> complex circuits requiring a dual-sided PCB, this is not so
> great though.  Here's an example...
> http://www.avn-> tech.com/stuff/speedo_conv_pcb.jpg
>
> The real
> problem is
> laying out the pattern on the board. I can draw some nice
> board layouts using a CAD program etc, but I've been using
> rub-on transfers to create the circuit, and it never looks
> professional. Been looking at the photo-sensitive board
> process, but that probably means I need a laser printer.
> Most photo-copier places won't let me put any special paper
> in their machines.
>
> However, I've heard/read that with the photo-sensitive
> process, once I get a transparency with the circuit on it, I
> can lay the pattern out under the sun, and don't even need a
> UV lamp.  (Lots of sun here in Texas!)
>
> I've seen the iron-on transfer system, but from the
> instructions, they seem like they would be a major hassle to
> get perfect.
>
> Any thoughts, or options I may be missing here? My priorities
> are low equipment/materials cost.  Labor is not a problem ...
> see, getting
> laid-off is not all bad.   :-)
>
>
> Cheers.
>
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