Electronic Circuits
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IR-12 Infrared Transmitter Circuits Tester - For Infrared Spy Circuits 
Built By Pete Zenner, Sioux Falls, SD. - Sept. 2013

The board for the IR-12 Infrared Circuit Test unit was designed using Express PCB because the layouts are easy to make. I don't have many suggestions once you've learned the program. A few simple hints when using this program are to increase the thickness of your connecting traces to .030", from the default .010". Draw the traces and pads on the green (bottom) side of the board. When you iron them onto a PCB later, they'll be oriented correctly.

The program often defaults letters and lines to the red/top side, so I double check them. The components automatically get placed on the top side which is OK because the red pads will be on the bottom layer. If you make a custom component with specific lead spacing, remember to save and name it. Lastly, the pads for the components should also be enlarged a little from the default. I use .062" square or round pads with .029" holes or .070" square or round pads with .033" holes. When you drill the holes, it's much easier. If the pads are too small, I sometimes tear the copper traces off the PCB when drilling.

infrared circuit tester circuit artwork
infrared circuit tester circuit top view
I discovered laminators are really convenient for the "toner transfer" method of PCB printing. I picked mine up at a thrift store. Once you've copied the PCB Layout to transfer paper (Press N' Peel or equivalent), just tape your transfer paper to the copper side of the board and run it through the laminator. NOTE: make a few tests... the laminator should accept PCB thicknesses. The benefit of a laminator is that it will provide a constant temperature and even pressure. No more smeared traces from hand ironing. The current PCB board thickness I used is .060", but because the laminator has difficulty feeding this, I am going to use .038" or thinner copper boards on the next attempts. The laminator accepts small boards only -- too much heat is lost with any board over 2"x2". Feed your board through the laminator at least 4 or 5 times to get a good transfer to the board.

Laminating provides a nice quick way to make a PCB. There's no difference, but instead of hand ironing the Press-N-Peel paper onto the board, you just feed the board into a laminating machine and comes out the other side. It saves me time from having to iron the transfer paper onto the board. I found a cheap small laminating machine (made by TDE) and it seems to work fine--except that I need to run the PCB board through the machine a couple times before the board gets hot enough to fuse the toner to the copper. Pete.

I think this was the first link I ran across using a laminator for making making PCB Boards:

http://www.pcbfx.com/main_site/pages/start_here/laminator_info.html
infrared circuit tester, circuit assembly chart
make the infrared circuit board using a laminating machine>
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Assembly photos for the IR-12 infrared circuit tester, by Pete Zenner
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Artwork 1:1
Topview Looking Thru The Board
To Get The Artwork - just do a right click of your mouse on the image and save it as - Somewhere in your files
Example Of A Laminating Machine