>I envision the process in three stages:
>
>1) Design: finish adding the goodies to the prototype, layout a PCB, then
>test and tweak until a rock solid design and board is complete.
>
>2) Prototype production run where a handful of boards are done with the
final
>design from the board house, which are then tested.
>
>3) Final run. The actual production run.

I would forget about "finishing the design" on the wire wrap circuit. Go
straight to designing the PCB adding the rest of the parts required to
finish the design to the PCB as you go. I would strongly recommend putting
as many pad sets for extra chips as you can on otherwise spare area if at
all possible, without increasing the size of the board.

Then get a panel of boards made at a 24 hr turn round house. This will give
you several PCB's at a good price, and back in your hands rapidly. Attend to
parts ordering/documentation and any other menial chores that normally get
put aside while you wait.

Now debug your layout and remainder of your design using one of these boards
you get back. If necessary build a second board with neat modifications to
it as a "shippable sample" to verify each and every mod you think you have
made to the first PCB you built up. Having verified that you have correctly
enumerated every mod on this second PCB, modify the PCB masters, adding
silkscreen and solder mask if necessary/desirable and get a production batch
of PCB's made.

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