Ok, I finally got round to finishing the box layout (5 days of trial to go in Illustrator). I decided to try to do the transfer with picture paper

Here the box is sanded off with a flat piece of wood and the transfer, white on black mirror image ready to go.




The side as well are sanded off and cleaned with acetone. Here they are coated with the spraycan to protect them during the etching process. I masked the top with tape to avoid having to resand it. Did clean of the residue tape with acetone. I used acetone in lack of lighter fluid throughout this process, which is a bad idea because it might come in contact with the paint and rub off. I did.



Now clean the top again and we're ready for transfer.

The important thing, I found is to PUNCH A LOT OF HOLES IN THE WHITE AREAS BEFORE YOU START. I used an exacto knife. Before I had to start all over again three times in a row although I had made cutout in large black areas. The punchholes will

1/ let air escape during ironing for good contact between toner and metal
2/ let air escape when you put it in water afterwards


For the ironing, I put it on the hottest position and ironed for a long time. Initially hold the paper in place and put the iron on one side on the box to let the paper film stick to the metal. Air bubbles are you enemies, iron them out. Don't worry about burning paper or smearing the toner. Just iron the hell out of it, every square milimetre.

After the ironing, toss the box in boiling hot water. You will see air espace throught the holes you punched.



Have a cup, a cookie and a smoke -- your 15 min break while the picture paper soaks. Maybe some extra hot water for the box in the meantime...

When the box comes out rinse it with cold water to let the toner set and the box cool down. You can then rub off most of the thick paper with your fingers. The remaining white film can be scraped off with a guitar pick or finger nails.





I masked bare areas between paint and toner with nail varnish, white nail varnish. Easier to use any colour paint, of course...

And into the etchant:







Box rinsed off after etching




It was ok, but I made the mistake of sanding it off at this point.





Paint applied for the cavities




Sanded off again (too much), already drilling holes.




With LED, stompswitch, knobs: