Buy an Axon, Axon II, or Axon Mote and build a great robot, while helping to support SoR.
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I just use BatchPCB, at $2.50 a square inch it is a steal. I just don't think spending all the time for DIY PCBs is worth it.
For the drilling, I wouldn't even try it unless you have some kind of drill press (Dremel, etc.) which will keep the drill bit lined up correctly while drilling. Doing it by hand is just asking for frustration and several broken drill bits. The bits should be as sharp as you can find. Don't scrimp with the drill bit.