Archive of the former Yahoo!Groups mailing list: Homebrew PCBs

As a followup to my recent introduction and questions, I've got two
more questions (well, two more for now ... !)

1) How many of you fabricate your own boxes in which to mount your
projects? For the latest board, I fabricated a box out of some thin
sheet steel, snipped to shape with tin snips, bent with a vise and
hammer, and tack welded the seams. It is workable, but crude. I'm sure
there's a better way?

2) Both of my recent efforts with TT have been double-sided layouts.
The first time, I tried to align using the edges of the board; the
second time, I thought I had gotten smart (based on something I read
here or elsewhere), and I lined up the two prints using a bright
backlight, then stapled them together to make a "pocket" into which I
inserted the board. Both methods gave me boards that were usable, but
not as closely aligned as I had hoped -- the second was marginally
better, but still off in some places by maybe .010" - .020". What's
the secret to getting a perfectly aligned double-sided board?