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  1. Personally, I use gerbmerge. It is free software and reasonably well documented. While it takes a little while to figure it out, ultimately it just takes two files to describe a merge. If you notice a bug on one of your boards, just fix the bug, generate the individual board gerbers and rerun gerbmerge. I have a Makefile that runs gerbmerge to regenerate the merged gerbers for fabrication.

    I am just providing gerbmerge as an alternative that may interest some people.

  2. I actually use the same process as Viktor. This procedure also works for the bottom side and layers 26 bNames and 126 _bNames respectively.

    For cutting I use a small proxxon circular table saw (model ks230) with a metal blade. With 0.6mm width, it creates nice, clean cuts. I put 0.6 mm wires in the _tNames layer to mark where the cuts have to go. This also gives a good impression of the space needed for cutting. Most manufactors suggest 0.6 mm clearance to the pcb edge for traces, when the individual boards are created accordingly, there was always sufficiant space for cutting.
    So far there was no relevat scratches to the bottom layer printing from the saw table.

    Hope that helps,

  3. It is also possible to use this script to achieve the same, but also without the board size limitations in Eagle light or free:

    It produces an eagle board file containing several sub-boards. The resulting board can be larger than 100x80mm limit and fully editable as long as no component is moved.

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