Homebrew PCBs

Barry, I went thru the same growing pains you are - except you have success with the photoresist.  I never paid the price (money) for the photo setup.

By far and away the best paper is the Pulsar toner transfer paper - that stuff just floats off.  I've used slick magazine paper with success and also the HP Presentation grade color laser paper is working good - just a hassle to get off.  Got to soak 20 minutes or so.

the boards MUST be clean - but I would expect no cleaner than required for photo etching, but with the pre-sensitized board, it's already cleaned. I purchase my PCB stock from a dealer here in USA - last batch I got 20 lb for $31 USD shipped to me.  It was a bunch of pieces, but the smallest piece was 3"X6" with several almost full sized sheets.  Some was really too thin, but still a decent price - all double sided.

After sanding copper with 320 to 400 grit sandpaper, I do a really good job of cleaning with alcohol.

I never had very good luck with the iron myself - I've been using the laminator for a while now - very happy with it.  In fact, so happy I ordered another as a spare.  $25 was so cheap.

Good luck,
Ken