>how many layer is the board? if its only a double sided board then i
>presume you could depopulate it, scan it and trace the scans.

Not quite, after depopulating it, you polish it so the copper is bright, and 
get the board house to photograph it to make the master. Agree it is really 
only practical with a 2 layer PCB, but not impossible on a multilayer one - 
if you have some suitable milling machinery to skim the layers off. 

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