Very interesting -- that's many more steps than I've seen typical DIY kits use, and the results look good, though it looks like you have to drill twice (once beforehand, once with the cured paste).
I didn't pick that up on the first time through. Could be a real pain for a complex board.
I only assume that because otherwise you wouldn't be able to see the pads well enough to drill accurately with the cured paste, and his example board looks like it has small features. You could restrict it to vias, too, skipping TO pkg and mounting holes (though may want them for strength).
You can try these track pins:
http://pt.farnell.com/harwin/t1559f46/track-pin-0-84mm-pk500/dp/1143874?Ntt=1143874
Thes track pins are definitely the way to go - very quick - just insert & snap off in each hole, go round then soldering both sides. Solder the top (wide) end first, while pushing down with the iron quite hard - this helps wedge them in, so the pin doesn't pop out when soldering on the underside.
For small holes down to 0.6mm OD, Mega do
these rivets, which are quite useable without the press tooling - just use fine-point tweezers to drop them in the hole solder then solder the underside.
while pushing down with the iron quite hard
Doing so will damage the tip's iron plating accelerrating its destruction. It is best to do any mechanical work before soldering surfaces together.
while pushing down with the iron quite hard
Doing so will damage the tip's iron plating accelerrating its destruction. It is best to do any mechanical work before soldering surfaces together.
Use a big tip. It's easiest to do it with the iron so it softens the PCB material as it goes in - the heat means you don't need anywhere near as much pressure as if doing it cold - not enough to cause damage - the pins are softer than the tip plating.
About vias, I've used the LPKF polymer paste, works well, it's quite simple.
As drawback, it is not very resistant (don't heat up it too much, like while soldering and desoldering many times), and it can cause shorts if you don't work precisely and...it costs! I think a single packet (3-4 small boards) costs about 5euro.
I confirm 0805 passives (and SOIC ICs, too) are handy, better than TH, IMHO.
EDIT: ...SMT is easy to work with...provided that you have desoldering tweezers or at least two soldering irons.