Homebrew PCBs

I just use a hacksaw (arm-powered!) with a fine-tooth metal-cutting
blade.  I can make a pretty straight cut (less that 1/32 inch or 1 mm
deviation), cut several inches per minute, and then smooth the edge with
a file or sandpaper block.

Since cutting the material takes less time than just about any other
step in the PCB making process, I haven't worried about it!

Cheers,
- Jan