Homebrew PCBs

Ted (and all),

Is it still possible that you might get lucky with a cheap (eBay) 
brand of replacement toner to resolve the problem? Plus, those laser 
rigs are so great, that you've at least got a really nice machine for 
regular prints even if you grab a cheap old one for this. 

FWIW, the 6L only does 600 dpi. I'm usually doing .016" traces, which 
can often ride between IC pins, and I'm OK. Ironically, the thin stuff 
is what I almost never have trouble with.

I mentioned some stuff about wet paper towels, but that was on regular 
paper transfers. I was having a lot of trouble with the paper cooling 
too quickly (often with metal xfers), and bubbling or lifting while it 
cooled. I was doing that on the final passes. (Just made me realize I 
can't remember what the heck it was that resolved the issue. Now I'm 
finally needing to do my next board.)

Yes, those edges are a PITA. I usually hit with a file at a really 
shallow angle (almost parallel to the board), and I'm trying to keep 
in a habit of either not running thin traces near the edges, or 
keeping a bit of excess past the borders. Sand paper and belt sanders 
have done really well for burning off the extra afterward.

Good Luck!

George