Ah! You couldn't resist open this mail! Good. I need curious and creative
people here. Imagine this:
Step 1: three FR4 boards 1x5 inches, just copper on both sides.
Step 2: another three boards exactly same
Step 3: machine three slots halfway in the first board
Step 4: machine three slots halfway in the second board
Step 5: slide the boards into each other so that you get a 'honeycomb'
Step 6: solder all the corners, there will be 36 corners.
Question: how would you do that? 
Screen print along edges and solder mask to enhance solder to wet in the 90
degree corners?
Use IR oven or VP?
How do you avoid 'hanging' solder?
How do you get a nice, even and conformal solder menisque (how on earth do
you spell that?)

Inge

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