There is a lot of info on this out there but a few things that took me a bit to figure out.
-I like to use Cupric Chloride its easy to obtain, and it doesn't need to get thrown away. It can just be rejuvenated with some Hydrogen Peroxide.
-For Cupric Chloride I found "Clear Developer Volume 40" for coloring hair that is %40 Hydrogen Peroxide. Helps to not water down the acid mix. Purchased at a beauty supply store.
-Pre-etch the board for a couple of minutes before applying toner.
-If using a clothes iron, tape the PCB design to the board. Using a big drill bit or a dowel rod, roll the PCB between the dowel and clothes iron. Toner usually sticks a lot better.
Working with Styrene:
I make a lot of things with this stuff, it comes in all thickness, but I usually use 1/8" thick pieces. I get scrap pieces from a screen printer.
- Some chips of styrene dissolved in Methylene Chloride (Acrylic Cement, available at hobby/crafts store) makes a viscous glue that easily welds styrene together.
- Only store or mix the glue in a glass container because, Methylene Chloride will dissolve most plastics.
- I've found that Krylon Fusion spray paint works best.
*I may be selling pieces of styrene in the future, soon as I figure how to ship it, contact me for Info