Charlie made his own Bus Pirate PCB and used LPKF EasyContac rivets (warning, page denies non-US IPs) to connect the front and back sides. He had to enlarge the vias to 31mils to fit the rivets, and suggests going even bigger if possible. There’s more discussion on Charlie’s blog and at CNC Zone.

The LPKF ProtoMat PCB mill is also worth a look (this page accepts all visitors). That would be great in our lab!

Via the forum.