Cutting PCB’s - recommendations, tools etc

[HankMcSpank]

I do mine same as Hank up to the point of getting it out of Eagle.
Here, I use the pcb-gcode.ulp to create the gcode files directly. Then I run Daedelus's Autolevel program to take care of variations in height and run these programs directly on my router.

I use CNC-USB (vs Mach3) as it has this Z probling/correction feature built in.

You can use your favorite units system directly with no conversions needed.

Can you add a bit more meat here? (not fully understanding what you're getting at ...do you mean with gerber conversion? I convert gerbers from imperial to metric as I've not found a way of getting Eagle to export gerbers in metric yet! That said it's only a 30 second overhead to do the conversion)