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16-09-2012 #2
I've successfully used 1.6mm double sided FR4 board with 300 - 400gm/sq cm copper (thats around 0.04mm thick) per side. In small sizes (Eurocard, e.g. 100x 220) it stays reasonably flat. I wouldn't use single sided as I think it tends to curl slightly and that makes it hard to get good resolution on fine lines. Also a lot of the stuff I do needs a ground plane anyway so single sided is pointless. The bit I've used is a 90deg v-bit from here though i got it locally off ebay and not used it enough yet to need to consider a replacement...
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