Step 4: Buggy Boarding . . .
There are other tutorials about making PCBs, so I’m not going to detail that torture here. I used the toner-transfer method. You can used the bitmap file to print out an image or use the Eagle Cad files. I used Microsoft Paint to print out the bitmap to the correct scale. Print a board image on plain paper and do a mock up with real parts first.
If at first you don't succeed, try, try, again. It took me several tries before I got a usable transfer. You can do some touch up with a Sharpie marker, or just scrub it clean and try again. I'm getting better at it. The deadline for the project was too close, or I would have looked into having them manufactured. If you go to that trouble, put me down for a couple.
Drilling the board was a bit of a trick as well. Dremel has a drill bit kit that has 1/32", 3/64", and 1/16" bits. I made a diagram (below) to show what pad is drilled to which size. Wear a mask. Breathing fiber glass dust is not recommended. The hole for the speaker is ½” . There is pad there to act as a pilot hole.