@Dave, I would love to see pics of your mill! Also, mill size, speed and feed. Have you tried cutting any solder mask's? I saw someone doing that on you tube with some .005 brass I think. Seems like I remember them holding it down with 3M or some other spray glue.

@Ioannis, That is a GREAT link! I think I have read the entire site, and I must say, it looks like a wonderful technique. Still unsure on solder mask and the via's sound a bit cumbersome. but for prototyping, sounds like fun.

@Darrel, Thanks for jumping in and carrying the flag for VSM! Without the advanced sim stuff, are you able to watch outputs like on a scope? So being able to compare timing between signals and such?