You are going to need a control board and etched power board. The power board needs to be at least 3 ounce copper. Ebay is a good place to look for heavy cheap copper clad PCB. For example:http://cgi.ebay.com/25-shts-Copper-Clad-Laminate-FR-4-060-9-x-12-3oz-/310244821519?pt=LH_DefaultDomain_0&hash=item483c084a0f
You could print the picture from this link and somehow transfer it onto a piece of heavy blank PCB, and etch it with a dremel if you have a ver y steady hand. The dimensions are 8"x6". This link also has the G-code that you can use to etch with a CNC mill or you could give the G-code to a machine shop.http://ecomodder.com/wiki/index.php/Open_ReVolt/Fab_Files
Picture 2 and 3 below is an example of an early power board I made with a Dremel.
You can get a control board from me or you can make the control board in your favorite PCB layout software using the schematic here::http://home.cogeco.ca/~tkooistra/Cougar_Controller_Rev2C_Schematic.pdf
And here are some pictures of the PCB layers:http://home.cogeco.ca/~tkooistra/bottom_layer_rev2C.pdfhttp://home.cogeco.ca/~tkooistra/top_layer_rev2C.pdfhttp://home.cogeco.ca/~tkooistra/component_layer_rev2C.pdf
A predone control board is Picture 1.
Pictures 7 and 8 are the power board top and bottom. The 8 solder spots are just where vias were added.
Once you have the 2 boards, you can go to step 2.