Creating PCB’s at home has always been a hassle. The basic methods available include manually laying out the traces with trace transfers (not recommended), photoreproduction (specialized, and expensive), or the use of a laser printer using the toner transfer method. This latter has been somewhat hit or miss for me, with variable results, until I did a bit of internet research and discovered an absolutely dynamite paper. Link. Also check out our primer in MAKE 02.
PCB Creation – Printed Circuit Boards for the Masses