It'll be a bit before I get to pics/video because I'm moving on Monday. You're right about the etch, photo boards are the way to go. I haven't used vero myself, but I definitely wouldn't try this on it. Too many traces winding around too many different places. The PCB fits nicely in a 1590D. It might be possible to get it into a 1590DD, but I have my doubts, as the number of switches and jacks is hard to work around, not to mention all the wiring. For the treadle I bought a crappy Rogue wah used for $10. Note that this project requires a stereo jack/cable for the treadle. If you can wait a week, I should be able to post some stuff.
Mouser has photo boards much cheaper than what you said:http://www.mouser.com/Search/Refine.asp ... sensitized
Also, Steve at Small Bear is getting some in that are large enough for this project, but he won't have them until September (his guess). For the size he carries, he's cheaper than Mouser, and the board I got from him work better.