i had a 2x2" peice of uncut pcb lying on my desk upstairs earlyer when i was cleaning my room and all my junk boxes separating **** from good ****, and crap from junk. i kept all the junk and good ****, discarding the crap and ****. needless to say my room is theoretically cleaner now, though it doesnt seem to have changed much by its outward appearance.
anyway i decided that since i had this piece of pcb, which was trimmings from my last pcb project i decided id make me a nice little power supply for my pi. lacking the parts to do a switch mode supply, i opted for a most basic lm7805 circuit, big ass traces, and places for one regulator, four capacitors, one schottky diode (for reverse polarity protection), one led, one current limiting resistor for said led, a 3-pin input header (same pinout as my diy battery packs), a 2-pin output header, and a barrel jack for 12v input. the board is small enough to fit inside the lego case i made for my pi, so i dont have to have an externally mounted supply (except for the usb hub im using).
i designed it as a one sided board where the other side is essentially a heat sink for the regulator with big holes where the parts go so alignment wasnt critical. i actually have heatsing over about 40% of the other side where there is only a handful of traces. dispite the fact that the heat sink on the regulator is grounded internally i isolated the ground plane from the heat sink area which in hind sight was probibly a bad idea. i could have had much cleaner edcge traces by side stepping pads right into the ground plane and out of the way. i also scratched a cat head into the corner with an exacto knife, i now have a copper clad drawing of a kitty on my ground plane which is about a quarter inch whisker to whisker.
the iron on step was an epic fail. i tried it again (it always pays to print multiple copies of the same design on the sheet of transfer paper) and it was no better. so i gabe up and started filling in the holes with a sharpie. and fixing mistakes (and drawing a kitty) with an exacto knife. so it took 2 and a half batches of my etchat to cut this thing (my last board used 4). i had to make an extra half batch because the etchant stopped reacting when i was close to done. also i found that sharpie ink doesnt last long in the etchang, i had to re-touch up between some batches to prevent dissolving a couple traces. but the results werent half bad. i didnt spend as much time on the cleaning i suspect. also tape offset. seriously scotch tape is thick enough to prevent large swaths of circuit board from getting ironed. i think in the future i will only tape one edge, and leave some space between it and any traces. and then iron to the side of it so it doesnt keep the iron from applying pressure evenly to the whole board.
also it seemed my etchant put out a lot of fumes this time. idk what they were but it smelled like a swimming pool. but when faced with the choice between doing what i whant to do, and chemical poisioning, i will always choose the former. i may stop handling the stuff with my bare hands though. tomorrow i get to break in my new dremel drill press since i finally got the pcb bits i ordered for it. its 4am, and i dont want to piss of the neibors,theyve been *****y lately.
tldr: you suck and should be on fire for not reading my awesome wall of text post!