''1. Do your design. I knicked the one on my Fuzz Face from deviantart. Resize, add, subtract, add text blah blah then REVERSE and MAKE NEGATIVE. I did this in the smashing free program Paint.net. It also has a plug in that will turn anything into a black and white 'stencil', which is useful for this process.
2. Print it out. It needs to be LASER toner on SHINY PHOTO PAPER. I don't have a laser printer, so I bought some shiny photo paper and convinced the old dears who work in my local library to let me bang it through the photocopier. This way, I can also adjust the density of the toner (get it as thick as you can!)
3. Take an enclosure that you've already given a darn good sanding (the more you sand it, the better it'll look), clean with lighter fluid, wipe off with warm water, dry etc blah blah, cut out your design, tape it face down on the enclosure. Then use a clothes iron to iron the buggery out of it. Press down, make sure all the edges are done, really go to work on it. I bought my own iron for this, as it rubbed all the teflon type non slip stuff off the bottom. Your missus won't appreciate that.
4. Wait for it to cool (your enclosure should be VERY hot), put it in some water, let it soak through and use an old toothbrush to brush away all the paper. It should go all mushy and just rub away. Keep putting it back in and letting it soak through once you've got the initial soaking wet paper off. This process shouldn't be rushed, but at the same time, it's not as if your restoring a masterpiece. A bit of patience is all required. Make sure all the paper is rubbed away and... voila! The photocopy toner has melted and stuck to your enclosure! Unless it hasn't, in which case, start again. Mask up the sides with masking tape, nail varnish etc.
5. Get your ferric chloride out. Careful, this stuff will dissolve any metal, and stain everything else a lovely shade of diahorrea. Place acid in a plastic container (you only need about 5mm in the bottom), with lid (puncture lid) and place in microwave until luke-warm. Put boiling water in a bigger plastic container, then place your acid bath in that. Have another container with cold water on hand too to rinse it off.
6. Place your enclosure face down in the acid, gently swill about a bit. Now here is where my method seems to vary from the accepted norms. Take it out, rub all the acid in with an old toothbrush. Make sure you do it all evenly. Place back in acid, swish about a bit, then take out and repeat toothbrush manouver. The idea is to 'invigorate' the acid. If the enclosure is getting too hot, place in the clean water enclosure and rub away all the etchant. You'll also be able to see how your progressing. Back to the acid, dip, scrub repeat until you feel the etch is deep enough.
7. Clean away all acid, give it a right good wash. Then spray with spraypaint, wait to dry, and sand the top until all the photocopy toner has gone. And Bobs yer uncle.
Other members will probably add their tuppence worth, and it's all relevant. I looked up a few guides, and knacked an enclosure before I came upon my winning formula. You might have to modify it a bit to get it to work for you.''