Warning: These blocking routines soon to be deprecated.  Work on servicing data phase via interrupts has already begun.

PCB (Revision 20008.37.3) surface mount assembly of 1 panel/10 boards:  set frame, attach stencil, apply paste, squeegee, place components, reflow, surface mount devices fully assembled.

Notes:

1. Strategically applying solder paste throughout cut-out area before printing requires less solder paste (even less than shown) vs. only applying it across the upper length of the stencil and helps retain proper squeegee angle throughput the printing process.
2. Apply constant pressure to entire cut-out area to prevent lifting while printing.  Notice more accurate amount of paste deposited on left-hand side.  Squeegee held in the right hand.
3. Place panel on flat surface when placing components.  Panavise induces too much instability when stuffing full panels.
4. Video entire reflow process through inspection window.  Difficult to document profile with a photo.
5. No-clean lead-free solder paste may actually require some cleaning after reflow.
6. Stencil design tips: link 1 | link 2.
7. Stencil and squeegee cleaning tips: >140°C water in conjunction with a pressure spray followed by deionized water followed by an isopropanol rinse.

A few more assembly tools to order:

Holding off a bit to see if anything else shakes out that could be useful to finish PCB (Revision 2008.37.3) assembly.

These 0805 components are hobbyist friendly, as anticipated.  By design, there's only one 0402 component and by default it is "do not install".

Smart Tweezers arrived, cool.  Immediately started playing with them.

Simply forgot to take solder paste out of the refrigerator last night.  Therefore, assembly of PCB (Revision 2008.37.3) postponed, $#!^!!!

Here's a glimpse of my next PCB design, forecasted as both expensive and "brainless", quite atypical for me.  However, it does fall nicely into the utilitarian category, fitting me to a "T":

Holding off a bit to allow bank account to recover.

1. Buy pastes according to manufacturing date, not expiry date.
2. Store in refrigerator at 5°-10°C. This doubles the possible storage period from the manufacturing date.
3. Most pastes should not be frozen. Cold storage lengthens storage time as chemicals will react more slowly and paste is more stable against separation. Storage that is too cold (<5°C) may cause crystallization of rosins/resins. Storage that is too warm may cause a loss of solvents and possible reaction of activators.
4. Use airtight containers.
5. Use a first-in/first-out storage system.
6. Never store beyond the usable date.
7. Store syringes/barrels in upright position to limit danger of air bubbles. Older formulations may require horizontal storage with (occasional) rotation to avoid flux separation.
8. Store paste in the dark as light can polymerize rosins.
9. Shelf life of paste depends on storage temperature, for example:
   1. At 7°C, some pastes can be stored for six months.
   2. At 20°C, some pastes can be stored for only one month.
   3. At 30°C, some pastes may be stored for just two weeks.

Tools already purchased to assist with assembly and rework: Metcal SP-200 Soldering Station ($201.50) with SSC-626A Replaceable Tip Cartridge ($16.14), Madell 850D Hot Air Rework Station ($266.26) and Panavise ($27.99).

Wow, finally "need" to order the BOM for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3), Yeah!!!

Which reminds me, still need to order the BOM and a few assembly tools.

Ordered a low-end reflow oven ($360 + $100s&h) to help with assembly.

The kit includes laser cut 5mm stainless steel plate / stencil (+/-0.00025 tolerance on holes), one board holder, solder paste, temperature marker, squeegee, ESD-safe gloves and alcohol wipe.  The pick & place hand tool includes vacuum bulb and vacuum cups with diameters of 3/8", 1/4", and 1/8".

Here's a scan of my attempt for a component placement illustration for PCB (Revision 2008.37.3). 

Asked board house to panelize ($0) and add e-test ($140) in preparation for full turnkey assembly quote ($3,176.53).  Needless to say, another plan needs to be constructed to assemble these boards (partially solved, see Desktop Stencil Kit above). 

Cobbled together a hand-written schematic for PCB (Revision 2008.37.3). 

Oh, and one final review of the PCB (Revision 2008.37.3) revealed an error (will live with it) in the silkscreen.

Ordered Brewmaster's USB to Juno Bridge PCB.  Here's screen capture, order confirmation ($207), and board layout design files (Revision 2008.37.3) for PCB Artist.