Where to start? To be honest, although this is open source, and I am releasing this under the most generous license, I'm not sure this will be the easiest to replicate and build. Etching PCBs is not always the easiest, especially when it is someone else design. That being said, I give you all the encouragement in the world to replicate this, or modify it to use as your own!

Your best bet is probably to download the EAGLE schematic and PCB layout and reproduce the board using your preferred methods. I have uploaded a PDF of the image I used to etch my board, but others may find it easier to make the trace lines larger, or re-layout the board. (My feelings won't be hurt).

Once you etch and drill the holes in the board, it is time to assemble the components. Again, I apologize if I'm leaving you in the dark here (admittedly I am), but there are plenty of board assembly and soldering instructions available on the web. Of note, I choose to install a IDC DIP connector so I could program the ATMEGA328 independently in a development environment, and then transfer to the production FLIGHTCPU when complete. This also simplified the actual board layout, as I did not have to think about inboard programming.

Once you have created the board, assembled the components, and loaded the software, you should be all set! Provide 6-9V to VIN and let the onboard regulator do the work to bring it down the respectable 5V. Watch for the status LED, it should blink periodically to let you know it is working. If there is no communication to the SD card, then the LED will stay solid.