I do !
Attached is an image of my Easter project.
There are 78 pins, excluding the JTAG header, on a Panda. That includes all the power/GND pins and the UEXT header.
There are also 40 pins on a WIZ812 ethernet module. There’s 8 pins on an 24LC256 eeprom. There’s 3 pins on a DS18B20 one-wire temperature sensor. There’s 3 pins as a OW header, and 4 pins for a serial port daughter board header. There are also 16 holes for jumper wires (this is a single sided board). That’s a total of 152.
On the (not-pictured) serial daughterboard, there are a total of 46 pins, including a MAX232 in DIP16, a DB9 connector, 5 capacitors and other jumper wires.
There are also 50 pins unpopulated on a standard Panda board, again excluding JTAG.
So, this weekend I drilled 152 + 46 = 198 holes using 0.8mm drills - of which I broke two and blunted two more. I then drilled 198 holes with a 1.0mm drill to make them big enough for my component legs (yes, that’s one thing I would have done differently in hindsight, 1.0mm straight away ). I then soldered 198 connections on the two boards, plus the 50 pins on my Panda to fully populate it. I then re-soldered several of these when I figured out I used the wrong DB9 connector and when I found a few not-complete solder joints.
I then modified the board to take an additional 4-pin terminal screw block that came about through scope creep (which I’m a bit bummed about - means the board isn’t as neat as it could have been !).
But now it’s over to software time to make sure things work as expected - so far so good, but I’ve only checked the scope-creep connectors, not the ethernet / SD card / RS232 / I2C eeprom.
Reflections on the whole thing. The reason I didn’t outsource this to Laen / DorkbotPDX or similar was that this was always only going to be a once-off project. I couldn’t see any reason to “waste” two other boards that I had to have made by Laen’s process. In hindsight, there is a LOT of drilling on this board. I should have just had it made and be done with it. It’s rewarding and all to have made it from scratch, but the economics of it all are not fantastic, I used a sheet of Press-n-peel (say $1), I used say $4 of PCB board, I used ~1/3 of a container of $10 Aluminium Persulphate etchant (say $3), I broke two 0.8mm drills (say $1), so that’s about $10 all up. I probably spent the better part of 8 hours doing things I wouldn’t have to do if I bought the board (drilling etc). Sure, I didn’t need to worry about a lot of things on my board design (solder masking, silkscreen etc) but on the whole, that would have been a much better use of my time and money than how I did it. But I’ve done it now and I have seen the pitfalls, and now I know better