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Paul, Great work, I just finally finished reading through the whole thread. I cannot wait till the new site is up.
As for CNC. I have built 2 cnc milling machine so far and have started a third. For future power stages, I am offering to mill the boards for free. just send me the copper boards and I will send them back done. As long as they will fit in a 7.25x19 inch area there shouldn't be any problems.
Also, that bit you've been using should be spun closer to 15,000 rpm's the higher the better. if you could do 30k you would be great.
On to the control board. I happen to have a good friend that owns a production shop built for assembling circuit boards. I could get a great deal on getting the boards built. His machines can place 50k parts per hour!!! All you would need to do is make the board surface mount instead of through hole. Were talking panels of like 9 boards assembled and soldered in about 90 seconds. then you just snap them apart and finish the few things that need to be done by hand, like the DC-DC converter and any IC sockets.
-Adam
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