Teach a redneck how to make a PCB

[turbo6bar]

I'm working on a fall project, and I need to have a PCB manufactured. I know very little about his stuff. If I can nail the details, I will likely buy 100+ PCBs. Basically, I want to mount 4 relay sockets and 4 fuse mounts along with power, ground, and signal terminals. This is simple compared to most PCBs, but the redness of my neck blocks the brain activity necessary to bridge the knowledge barrier.

Anybody BTDT?
How do I lay out a board? I don't need a prototype, due to simplicity.
Recommended PCB manufacturers at reasonable prices? I think this board should be less than $5-6 when generated in volume.

Mucho thanks
Jürgen

[MichiganMat]

http://www.pcbexpress.com/
or
http://www.expresspcb.com/index.htm

They should have tools to help you with your layout and they can fab them for you. We used theses guys in college a lot.

[adrian jaye]

turbo,
not enough space to do a full procedure but essentially what you need/to do is: that is if your diy YOURSELF

1> draw up your circuit ON PAPER
2> get your copper PCB, copper on one side, fibre the other (double sided as copper bothsides, over a fibre sandwich)
3> either use transfers or a PCB pen to transfer your circuit to the copper side of the PCB

4> or use a clear laminate sheet and draw the circuit on
a) put this on the copper side and into a UV box) this then creates a circuit to be etched

4> get your etching solution (usually a suplher based liquid), put the copper board into said solution, leave for 20 minutes or so, all the copper has desolved off leaving the copper tracks

5> clean the board off, drill holes, mount and solder

easy