David,
I think the track widths and spacing - and the pitch of some of the ICs may make this board difficult to make using a router.
I learned a few years back that it was often better to get a professional pcb manufacturer to make the boards - and for a SMT board like this - the solder resist is essential for bug-free soldering of the FPGA.
The cost of boards from China has fallen so much that boards from China are very cheap. Shipping often costs more than the boards.
For example, you can get 10 double sided boards sized 100mm x100mm for $5 from
www.pcbway.com
Indeed a myStorm re-jigged in KiCAD on a 100x100 board might make an ideal educational board, and 50mmx50mm is an ideal size for a double-wide pmod expansion board.
If I were redesigning myStorm on a larger board, I'd probably use 0603 SMD components - as these are much easier to solder. The RAM chip and the microSD socket could be relocated to the top of the board - to eliminate two-sided assembly, and the Pi-header restored to a full 2x20 pins allowing a PI or Pi zero to be plugged in directly.
There are so-many ways of re-spinning this board, that we are happy that the community comes up with their own ideas.
The eagleCAD files are in the repository - here - and I believe that KiCAD will accept eagle format files as an import.
Probably the hardest part of the project was deciding the role of the STM32, and how exactly it would provide the programming supporting role for the FPGA. This has effectively been sorted by IceBoot - our programming firmware - provided by forum members Richard Miller and Alan Wood.
Most other ICE40 boards use a combination of the FT2232 dual USB interface and a large SPI flash memory - but we chose the STM32 processor route - because it was cheaper and significantly more versatile.
The first boards were assembled by hand - by Alan and I working over a weekend last July. It was a struggle to place al the 0402 components accurately - but with good light, a x10 magnifying lens and a steady hand were were able to get 3 boards assembled.
There is another ICE40 board intended for home construction - called the Kefir Board - which uses the same FPGA and has it's pcb CAD in KiCAD
http://fpgalibre.sourceforge.net/Kefir_en/index.html#tp30
You might also wish to look at the Olimex boards - as they also are designed using KiCAD - and they cleverly make use of an Arduino to program the bitstream flash memory.
