As for cnc router stuff you don't have to pay for plans if you don't want to. I have built several. There is also some good free software and lots of hobby level stuff to you up and running. I use a cnc mill for drilling the through holes.
I personally (for simple boards) use pre exposed boards and the laser printer to print on transparency. Then uv expose the board- then etch. I also converted over to mostly smd and have no problems making boards for 44 pin qfp.
I use eagle pcb for the design, like it a lot. For real boards I use expresspcb. they are about 15 miles away so for me they are a logical choice.
I always wanted to do a direct to copper thing too. I was thinking along the lines of a dye-sub or a thermal wax transfer version.
chad
When the going gets weird, the weird turn pro.