Making circuit boards is a nasty and tedious job, but it is cheap.  Through much pain and experimentation, i’ve found a reasonable way to make them using tips i read on the internet.  I lay out the design using ExpressPCB’s free software, then print it out on Staples brand glossy photo paper.  Then you iron this on to a copper board using a bunch of pressure.  Soak the board in water and rub off the paper.  If all goes well, the black ink from the laser printer will stay on the board.  Then to etch the board, i use a disgusting mix of muratic acid and hydrogen peroxide.  It is nasty and dangerous, so i think i will switch to ferric cloride.  After etching, i drill out the holes using a solid carbide bit.  The annoying part of this whole process is the ironing of the paper to the copper board.  if you don’t really get it good, some traces will not transer and crap like that.  for small problems, you can touch up with a sharpie, no kidding, it works.