The following is a crib-sheet to aid exporting gerber files which can be used to manufacture PCBS.
The following is a library of protel footprints and schematic components developed by the UNSW Solar Racing Team. If you develop any further components or footprints, please contribute these back to daves.pcb@cse.unsw.edu.au:
NOTE
Many through-hole components , like resistors and capacitors, have very small
pad sizes in the standard component libraries.
These pads are too small to be mechanically robust for single sided boards.
They are also so small that they are hard to solder, even with plated holes.
If you are making a single sided through-hole board and you use pad sizes
that are considered too small, the board might be rejected and you will have
to fix the pad sizes. This will mean editing the libraries or creating your own footprints (this is actually quite easy).
Draw the border on a separate mechanical layer (this defines the cutting area for the board). Make sure this mechanical layer is exported when you export the gerber files.