Homebrew PCBs

A diamond blade band saw for stained glass works good and a small 
scroll saw works even better if you can find the diamond blades. Many 
years ago I picked up a broken diamond band saw blade from a glass 
shop and cut it in pieces for use on my scroll saw. I brazed small 
tips on each end to allow clamping in the scroll saw. This setup 
really works good and I have been using this same blade and saw for 
over fifteen years.

Another idea is to use a pin router. The router tool is fixed over 
head and a pin is pushed into the table after drilling a hole in line 
with the router head. The table pin should be the same diameter as 
the router bit. The router head is lowered until the bit just clears 
the table mounted pin. A fixture is made from masonite, plastic or 
other easy to machine material. Line up and clamp the fixture to a 
drilled board and use at least two existing holes in the board as a 
guide to drill into the template. Make the fixture holes slightly 
smaller and use cut to length drill rods for pins. The board will now 
fit over these pins and can be pushed along to table mounted pin and 
routed.

Now you have a device to rapidly cut your finished boards to size. 
A fence can also be used for making straight cuts. This beats 
shearing if you are making more than a few boards. Almost any shape 
can be cut.  You can also stack up to three boards on this type of 
fixture depending on the spindle power.  I have even seen this done 
on a regular drill press using the highest spindle speed. With this 
arrangement you can even route internal holes and shapes if the 
spindle can be moved up and down.

Tom