Well, it sounds like we're talking about the same thing. 10cmx10cm
is pretty typical for me as well... The board pictured on the
earlier site post is ~7cmx10cm. I'm using a >5 year old HP laserjet
5L that's been working for me pretty well (2nd genuine HP toner
cartridge). I use a paper laminator as the fuser and magazine stock
as the transfer medium. I too had somewhat dubious results with the
press n peel stuff; but I was using a hand iron at the time. The
critical part, as with what you say about the spray photo resist, is
to get the stock very clean --otherwise the toner doesn't perform
well. When I have dropout problems it's usually due to not cleaning
the board properly, not cleaning the board edges when I cut down
stock (jagged edges left by the linoleum knife can give the surface
an uneven pressing in the laminator), or not getting the board hot
enough (too few passes through the laminator). All of this can be
corrected quickly, (clean the board and start again). With a little
practice you can get it right most of the time with no dropout.
One thing that this method won't do is large flooded areas --at least
with my printer. I don't think the HP 5L puts down even coverage
when covering large surfaces. If I need to have flooded regions, I
go through with a staedler marker and touch up the fallout.
For quick and dirty boards, you can get a lot of milage out of this
method.
I understand you've got a printer/photo process that works well for
you, but maybe someone who has a different setup might be able to get
results they're happy with using a laser printer they already have.
-Dal
PS I'll be putting a few more photos and fixing the howto text soon.
http://wheedal.dyndns.org:8255