There are many ways to built a DIY PCB. Some of the more popular ones are the toner transfer method, and the UV exposure of PCBs. Both methods require lots of trial and error.
Here is another way to go around building you PCBs. Pourcirup posted a tutorial on how to convert an old ink-jet printer to print traces onto a PCB. It is still being refined but the initial results look promising.
Via Adafruit.
Don’t dream your dreams, live them… :-)
That’s how we do this at shackspace in Stuttgart, Germany:
http://www.youtube.com/watch?&v=_DGUUoK_XTA
Greetings,
Michael
PS: Nevertheless a cool project!