Prototypes

I use a small battery operated angle grinder with a thin disk for metal cutting. Always wear gloves and goggles when doing this kind of work! (Phots were taken to illustrate the method without the angle grinder running.

You can also use a Dremel tool with a small cutting disk to do the same thing, but I prefer to use the battery operated angle grinder. Though I sometimes use the Dremel tool to refine and sharpen the point in the middle of the drill bit.

I start by reviewing the circuit diagram that I want to transfer into reality; and, then I sketch a physical layout of the components to get an idea of where all the joining (my "islands") of components takes place. I find this a very useful exercise, because I often find a more efficient layout after I have completed the original layout drawing of the physical components. It also confirms that I've transferred everything from the circuit diagram correctly.

I now use a small drill or Dremel tool to place a hole at each of my black marker pen dots. This hole acts as a guide for the modified drill bit that is used to cut the "Islands". (If I am using double-sided board, I will drill a few extra holes through the board to solder a thin wire through, making sure that both sides are connected as the circuit ground, or 'earth'.)

I cut my "Islands" using the specially prepared drill bit. I then smooth any rough points/raised copper by gently using a file over both sides of the surface of the board. I usually scrub the copper with steel wool/cleaning pad to make sure that I have a nice clean surface to solder components to...

Now I lay the board down on a piece of paper to use it as a template. Through each hole I place a small mark using a pencil/graphic pen (something thin enough to go through the hole in the centre of each "island") to indicate where my "Islands" are located.