Homebrew PCBs

Ron - Thanks for the pointer to casting group. I joined that, see a 
huge number of posted messages and I will look through some of those 
for information.

I was defnitely looking for something quite inexpensive - on the 
order of my investment in toner transfer PBC process. I would not 
mind the expense of a vacuum chamber to remove bubbles from rubber.

I have heard the warnings against using hardware store 
Silicon "calking" for electrical wire potting.  I have tried potting 
connectors using some automotive gasket compound. While that had a 
nice "rubber" feel to it, it did not seem to really "glue" itself to 
the wires well. I have dripped some 5 min epoxy into things like the 
RJ45 plugs to help anchor wires. That seems useful in limited 
situations.

Any pointers to what to ask for as a molding compound that would dry 
reasonably hard are stick well to insulated wires. Is "silicon 
rubber" a well known description when looking for this material?

If we stray too far from PCBs or the discussion gets too long I'm 
happy to take this away from the newsgroup. But making high quality 
cables seems pretty closly related to making boards, as most of my 
electrical projects have cables/connectors with them.

Thanks for the data so far. - dale