How To Make PCBs

First thing to do is make a schematic in EAGLE Layout Editor. Once you have done this you can then design the layout using Eagle too. Making schematic first helps because Eagle will show you clearly if you make any mistakes with the PCB.

Here is an example I will use, it is the prototype line stage used in my preamp:

Print it out onto some semi glossy photo paper. Be sure to select "solid black" in the eagle printing preferences and also un-select silk screen layers so that you only see pads and traces:

Then quickly take this paper, cut out your design and place it face down onto some blank PCB board. Then use an iron and press the design on to the board. Use A LOT of pressure and ensure all parts of the design make good contact with the blank PCB. Keep it pressed for at least 5 mins. I have found that having steam on/off makes no difference.

Then take your blank PCB with the design stuck on to it and soak it in soapy water for about 10 mins to loosen the paper:

Then CAREFULLY remove the paper. Be sure not to remove any of the black ink traces because these are what stops the acid in the etching process. I use a kind of rubbing motion to remove the paper. Keep it wet all the time so that it separates easily from the copper board.

Done and ready for etching:

Get some etchant and just follow the instructions for the dilution level. I just use a normal ceremic or glass bowel. Ghetto style:

Add boiling water from a jug:

And slowly swirl or rock the bowl around. The liquid must be always moving over the copper board to get it to etch properly.

Done!

Now give it a rinse in cold water and scrub the black ink off the PCB with a scratchy dish cleaner thing or steel wool.

Voila, you have a custom designed PCB:

Then all you need to do is drill out the holes and start mounting the components:

It will take maybe a couple of tries to get the hang of it but once you've got it you can produce perfect PCBs every time.

Tips for making PCBs:
www.expresspcb.com/ExpressPCBHtm/Tips.htm
Another guide like mine:
http://homepage.tinet.ie/~ei9gq/pcb.html
Some points to note:

• You can't do it with Inkjet printers, the ink doesn't stick, don't bother trying.
• OKI LED and regular laser printers work well.
• I have only used matt photo paper and have always had perfect results, although glossy would probably work too. Otherwise you will have to experiment.
• Once the design is stuck to the PCB put a blank piece of paper over the design and then rub and twist the iron while pressing the print on the PCB. This gives better coverage and makes sure it sticks on all parts of the PCB.

Here is some pics of another design I made (the soft-power circuit in my preamp):






This tutorial taken from No Spesific Topic