The PCB is a double sided board with a number of surface mount components. I have deliberately designed the board so that through hole plating is not required. Where vias have been placed the builder can join the top and bottom copper planes with a wire link soldered between both halves of the board. All resistors, mosfets and fuse holders need to be soldered on both the top and bottom of the PCB.
My board was made at home using the toner transfer method, so can easily be made by anyone at home. There are numerous websites on the internet describing this method. The only trick is to align the two halves of the printout beforehand. I do this using a lightsource shining through the prints. Once they are accurately aligned they are taped togother using masking tape. This is then aligned on the copper clad board and taped in place a second time. Three alignment holes, I use a 0.8mm drill bit are then drilled through the both the board and the plots outside of the board area. These holes will be used to align the plots once we transfer the toner to the copper.
A word of warning when printing out the artwork. Make sure that the printout is to the correct scale. You can place the 40 pin IC or socket onto the printout to check if it is correct. Various printers have been known to print either too big or too small. Also do not select scale to page on the print settings page. Done this once before myself, only discovered it after trying to solder the IC socket in place.
The surface mount components that have been used can easily be soldered using a fine tipped soldering iron.
The artwork can be downloaded on the Downloads page.
The circuit and pcb was designed using the freeware KICAD software suite. The original PCB layout files are available for download on the Downloads page.
The software used to create the schematics and PCB can be downloaded from here. There is both a Windows and Linux version available.