Homebrew PCBs

--- In Homebrew_PCBs@yahoogroups.com, "Kev Pearce \(kevp.com\)"
<email.me@k...> wrote:
...
> 
> 1). Cutting boards
> Does anyone know of a suitable mini saw table/inverted router type
setup to accurately cut PCBs to size?
> I know Dremel do a few add-ons for their hand held drills, but are
they any good?
> Is there any other kind of hobby/craft mini-saw table that could do
a nice job of cutting PCBs?

I have used a shear (with a nice clamping bar) for a lot of PCBs.  For
FR4, it really works well.  I have not had any damaged traces or vias
but I avoid traces within 100 mils of the edge as others do.  Its
important to note that the clamping bar makes the cut all that much
cleaner.  Its also so much faster than any other way.  Slide the board
in, line it up, shear and you're done.  Maybe a quick sanding of the
edges.   A couple of minutes at the most.

Sawing, routing, etc is just plain nasty.  I have used a 1/16" router
bit for this purpose - it is slow and creates a mess, even with a dust
collector. 

However, phenolic does not shear well at all.  Its just too brittle.

Each to his own...

> 
> 2). Drilling
> I can't really see any other way than a Dremel by hand...

I use a drill press.  By hand can work but a press is 10X better,
imho.  You can get "counter top" models for <$100 new and I see them
all the time at local (seattle) auctions in the $50-75 range.  With a
decent cross sliding vise you can drill with good accuracy.  Plus a
drill press is pretty much required equipment in any self-respecting
shop :)

> 
> 3). Silkscreen Top Component Layer
> Anyone know of any inkjet ink/paper/system that can be ironed on to
the top surface of a board to give component locations/orientations
etc. Any a nice cheap home solution? Does have to last forever just so
the boards can be assembled with less faults ;-) I though about doing
double sided boards and using the top copper side purely as a layout
layer without any connection tracks at all.

As was said, use toner transfer (after etching) to do the legend.  Its
easy and it works pretty well.

> 
> 4). Solder Masks
> Like the silkscreen at no 3) any kind of inkjet ink/paper setup that
will iron on solder masks?

I'm still looking for an easy way to do this.  Please post anything
you come up with.

Phil