I have some 8x12 sheets of copper clad board that I cut to size for the PCB. I use a very sharp utility knife and score both sides and then stick it in a vice. Putting constant pressure on it one way and then the other it will make a nice clean break and is a lot less messy than cutting it with a dremel or other cutting device.
So I got a decent toner transfer despite my new iron. It is a good one that was just getting to hot. I have done several projects, but this one was a little more detailed so the transfer needed to be a little better than my previous ones. I found that a lower temp setting with lots of pressure was my best bet. I tried a couple of different papers and had the best success with a matte style paper. I had to do some very minor touch ups with a Sharpie marking pen.
I also decided to make a bubbler for etching this project and I'm glad I did. I used 2 parts hydrogen Peroxide and 1 part muratic acid as an etching solution. In the past it's taken a couple of hours for my projects to etch in a glass dish, but with the bubbler it took less than 5 minutes. Good thing I was paying attention!
After the etching I went over the traces with a continuity tester because I was pretty sure a couple of the traces were touching and sure enough they were. I took a very sharp utility knife and ran it in between the traces to cut whatever copper was still touching. Worked like a charm.
Here is a picture of my board ready to be drilled and populated. I will update it as I go. Monday I will be ordering parts from Mouser.com using Gastric's definitive list.
