Hi Chuck, I`ve been using photo etching. I made a UV exposure box a while back:
http://www.raynerd.co.uk/?p=493and it has taken a long time but I`m getting better at etching recently and have had much more success with this method. I had a bit of a disaster when my power supply went awol and started feeding the wrong voltage to my UV LED box which is strange because the results ended up being that the photoresist
wasn`t broken down properly (I expected with a higher voltage the UVs would be more intense but perhaps the LEDs were being over driven?).
I`ve never used the toner transfer method so can`t help you there but what I would advise it to go back to Kwackers original post on CNC zone and around post number 346, page 29 there is a post by "Lucas" in which he provides an alternative copper screen and silk screen with much bigger tracks. Even with my "improved skills" at etching, I`ve been using Lucas` pcb design as it is just much easier to produce and is more forgiving in terms of errors in the etching. Infact, even when I was having the issues with my LEDs, I still got a working board from it, despite the etching process being a shambolic effort!!
He adds an extra cap across two LCD lines which I`m not sure about as I`ve never done this myself and they aren`t on Kwackers pcb. There is also an extra cap across the area that is regulating the voltage. But the board works 100% and the pcb is good.
I`m now back at work but if you are still struggling in the next few weeks, let me know and I`ll see if I can get one etched and sent over to you.
All the best.
Chris