Homebrew PCBs

Hi Matthew,
--- In Homebrew_PCBs@yahoogroups.com, "Matthew Mucker" <matthew@...> 
wrote:
> I'm new to the DIY-PCB scene. I've just finished my first test
> etch and am just overjoyed at the results I was able to achieve
> my first time out of the gate.

Congrats.  Have you tried ink jet transparencies for transfer?  I 
tried paper with mixed results.  With inkjet transparencies, there's 
less effort involved to prep the board for etching.  After ironing, 
just let the transparency cool slightly and then start lifting from 
one corner.  If some toner hasn't transferred, just replace the 
transparency and iron more; assuming you haven't removed the 
transparencly completely so alignment doesn't become an issue.  
Another advantage with iron/transparency is you can monitor toner 
melting and apply heat/pressure where needed.  I like to almost close 
lead holes so I can use them as pilot holes for the drill bits.

With transferred "properly", there's no toner left on the 
transparenc; pictures in my album.  Still should do the 
toothbrush/soap cleaning to remove any residue from the transparency, 
but no paper fibers to deal with.

As with paper, not all inkjet transparencies are equal.  I'm using 
some HP inkjet transparency that I bought in bulk.

The only downside I've seen is minor pitting because toner coverage 
isn't as good on transparencies; but it's purely cosmetic.  I go over 
ground planes with a Sharpie if it looks like pitting will be ugly.

I've tried running inkjet transparencies through several laser 
printers (HP, Lexmark, and Xerox) and have never had a problem with 
the printer getting jammed or otherwise damaged; YMMV.

> I now need to look at drilling my boards.  Does anyone have any
> recommendations on what drill bit sizes I should get for general
> through-hole work?

I prefer to use #69 (0.0292") for most holes, #65 (0.035") for 
headers, and #60 (0.040") for trimmers.  These sizes give a little 
friction on the leads so they don't fall out so easily when soldering.

Saw the link that someone posted.  Also take a look at 
drillbitcity.com.  They have assortments and shipping in the US is 
better; a few dollars for 20 bits with holders vs. $10 for that other 
place.  They have 10 piece assortment for sizes 60-69 that should be 
around $11 shipped in the US.  I'm not affiliated with them; just a 
satisfied customer.  These are resharpened bits, as are all of my 
other bits.

Regards,
Dennis