Fabricating the board was relatively straight-forward using the excellent tutorial which is here
http://fab.cba.mit.edu/content/processes/PCB/modela.html.
One very useful tip we found was that if you are using a brand new 64th" tool it is a good idea to set the tool speed a bit lower at 3mm/s until the tool has been 'broken in'. Apparently new tools are quite brittle and can break easily.
This is the result:
Soldering the components on the board was very fiddly and required 3 hands to hold down the components, hold the solder and the soldering iron. I couldn't really get going with the pre-soldered pad so I made this instead:
Then, following Neil's video instructions to the letter I uploaded the firmware to my board using AVRISP 2 and was amazed that it apparently seemed to work first time!!