Homebrew PCBs

I've done the stitching thing before but all those little loops tend to 
get in the way.  I suppose 28 gauge bare copper wire would do too, but I 
worry it would tarnish and become harder to solder.  The 30 gauge moves 
around too much in a 13 mil hole, too.

What would be nice is if I had a cutter that always left a bulge on the 
end of the wire - once you insert it and cut it, it *can't* fall out.

I suppose one could machine a small mandrell and press die, precut a 
bunch of copper wire a bit longer than the thickness of the PCB, and use 
a drill press to press-form them into place like rivets.

Now, if we could pre-cut the wire with a bulge on one end...