Homebrew PCBs

Hi all,

As a total n00b to homebrew PCBs, I've been struggling for the last
couple of weeks to get artwork onto the copper intact.

I must have made 20 or more attempts with the clothes iron, each time
getting most of the toner onto the board, but missing entire areas, with
intricate traces too fine for touching up by hand with the etch resist pen.

Also made a few failed attempts with the special iron-on transfer film;
IMHO, that stuff is not worth the money.

But Lady Luck was kind to me today. I found a used working Ibico PL-260
laminator in a Cash Converters store for $35 (approx US$25)!
Four spring loaded rollers, 6 motor speeds, digital temp control, perfect.

So the approach that's working for me, /finally/, is:

1. laser-print onto HP Gloss Inkjet photo card

2. scrub board with green plastic kitchen scouring sponge

3. clean copper surface thoroughly with acetone (I used my
   wife's nail polish remover)

4. 4 or so passes through laminator, with slowest motor speed, and
   temperature set to 160degC on more - feeding in corner first

5. peeling the card off very slowly while board still hot, in a very
   slow bending motion

   (I could hold the edge of the card along a glass tumbler, or other
   cylindrical object with 8cm or more diameter, and gently 'roll off'
   the card around the tumbler, so as not to tear off huge chunks of
   toner).

6. touch up artwork with etch resist pen (very few imperfections, so
   this was quick and easy).

7. etch in warmed ferric chloride

8. gently remove toner with acetone, but only when ready to drill and
   populate the board.

So to newcomers, I would strongly advise against the clothes iron
approach - unless you're lucky, and have a special 'feel', this will
likely drag you into a time-wasting world of pain.

Get a laminator - a decent one with spring-loaded rollers, speed and
temperature control. Either just find the money, or put the time/energy
into finding a cheap used one. You'll be glad you did, when you end up
with crisp, clear artwork on the copper.

For the experts here - if you can suggest any refinements, I'm all ears.

-- 
Cheers
David