Ha! that sounds pretty much like the plan I had in mind. I'll give it a try and tell you how it went. Thanks!I agree that alignment is a major pain however the few times I have done it I put extra pads in opposite corners of the layout, stuck one side of the layout to the PCB, drilled the smallest hole possible (0.3mm in my case) through the centre of the alignment pads, put needles though the holes and then aligned the layout for the other side on the needles. It wasn't spot on but it was good enough for things like 0.1" pitch PCB headers.