Homebrew PCBs

Jan,
About cutting FR4.... I had the same experience using using cutting
blades even when labeled for metal cutting.
I did find a solution, but requires some work.
I use Junior Hacksaw blades, I have to grind them to fit by scroll saw
length. As the portion of the blade that does the cutting is limited to
about 1/2" on my scroll saw I also grind down the width of the blade,
this helps in steering the FR4 while cutting.
The effort does pay off, one Junior Hacksaw blade will cut several
"feet" of FR4.
Form some time I looked for Junior Hacksaw blades in my local hardware
store, and even a specialist store and could not find them ! I finally
ended up getting family to buy the in the UK and ship them here.... A
few weeks ago I had a plumbing problem and ended up at Home Depot in the
plumbing department only to notice that's where Junior Hacksaw bladed
and saws are sold ! They are not called Junior Hacksaw in this country !
The Stanley Part number (form UK) is 3-15-905  I seem to remember they
called them mini hacksaw at Home Depot.

If you need me to post a photo of a prepared blade, let me know.

About Through Hole plating:
I discussed this process used by my favorite PCB shop and it does NOT
involve electro plating.
They simply "activate" the holes with a solution (I'm working on finding
the formula) and after that the board is place in another solution
containing copper. The process does not involve electroplating at all.

As soon as I have the formula for both solutions, I'll test and
publish...

Hans W