I purchased two Sick of Beige Bus Pirate v4 from schazamp on the DangerousPrototypes forums a couple of months ago and have been dragging my feet assembling them. I used hand soldering for the SMD parts on my DIY Bus Pirate v3 bur for v4, I wanted to try making a solder stencil and reflow using a hot air rework station. There have been several articles recently about etching copper and aluminum stencils and also a recent article about using a Cricut to cut a stencil out of overhead transparencies.
Via the contact form.
Check out the video after the break.