Homebrew PCBs

Got one done:

http://www.delorie.com/electronics/usb-gpio/

The inner core is 1/2oz 32 mil DS.  The two outer layers are 1/2oz 8
mil SS, taped on with 3M 7953 laminating adhesive.  TT (Pulsar), FeCl
etch, MG Liquid Tin.

Lessons learned:

* Keep track of which holes are which sizes on which layers.  I got
  this wrong in a couple of places, and had to use an xacto knife to
  cut through the outer layers.  There were a few places I drilled
  where I shouldn't have, but those were fixable.

* My process "bloats" copper, so I need to print it shrunk to
  compensate.  I had to "edit" the etch resist before etching, and
  still had some shorts afterwards that I had to fix.

* I still can't manually iron on toner with any success.  I tried the
  glossy magazine paper instead of the coated paper, just to see.  It
  seemed like it would have worked, if only the toner had stuck to the
  board better.  There's a fine line between "does stick" and "smears"
  that I keep passing through.  I didn't try it with the laminator, as
  I was trying to use up some 1/16" stock.

* How to do fast vias: Wrap solder around the board, to hold it off
  the table a bit.  Cut off a few inches of bare wire wrap wire.
  Stick wire through hole, solder, cut, repeat.  Flip board, solder
  all the little bits of wire sticking out.

* Pin 4 is not ground on mini-B connectors :-(