As the title suggests , this is a failed DIY - read ahead at you own risk
Having done the interior lights and spoiler brake lights with LED's , I decided to convert the boot lights as well , but using DIY PCB's. The DIY kit was purchased from EBay. Theoretically , the basic steps involved in etching a PCB are :
- Create the board layout using a PCB software . I used PCB Wizard. Various other software are also available e.g. ExpressPCB , Fritzing (Multi-platform)
- Transfer the layout using a laser printer to Toner Transfer Paper/Photo Paper and iron onto copper clad board
- Etch the board using Ferric Chloride or other etchant
- Remove toner using acetone
The kit available on EBay is pretty self-sufficient and includes most components you would need to make a PCB. The only other things required are a laser printer (inkjet will not work) and familiarity with a PCB design software.
The intended board was to have a simple 3x3 LED array , resistors and a voltage regulator. This is what the output looks like , printed on Toner Transfer Paper (comes with the kit).
Also featured is the 5cmx4cm copper board
Took me the better part of the afternoon to get the layout correct - component placement , printing at 100% , making sure all edges line up , trace width , hole sizes etc.. anyways , moving on
Here is the design ironed onto the board.
Red flag I failed to notice - some of the holes already looked warped. The toner probably got smudged due to too high a temperature during ironing and further smeared by incorrect rubbing. The difference from the design on paper is evident. There everything is sharp and all edges are well-defined.
After this the board was etched using a Ferric Chloride solution. The packet of etchant was wrapped in around 10 layers by the seller , and for good reason too. It stains everything it comes in contact with and should be handled carefully.
To etch the board , you can either just put it in the solution and move it around. Alternatively , you can take a sponge , dip it in the etchant and rub away lightly on the copper. i used the second method and it was surprisingly fast. Took me about the 4-5 minutes to get all the copper off. It is suggested that you leave as much copper on the board as possible. While this may consume more toner while printing , it significantly reduces the etching time. The resultant board with holes drilled with a 1mm bit and a dremel :
No go !
A pre-requisite of drilling the holes accurately is that the transfer should be fairly precise so that the holes have well-defined centers. The centers are obviously etched leaving you with a dimple surrounded by copper. The dimple acts as a guide for the drill bit. Since the holes I got were warped , the drill bit wandered all over the place and actually stripped some copper for some of the holes. On the brighter side , the component placement/sizes were spot on.
I will just call this Board Rev. V1 and take another attempt in the coming weekends !