Curtis,
> With that array of segments, I could then use cairo to draw the
> background before rendering the layers. I could tell it to "subtract"
> the soldermask from the background as the first step and then continue
> placing the other layers.
I don't think the overall board clipping would be that hard, since
cairo will do it quite simply. Once you extract the geometry you want
for the edge, you create a cairo target, draw a path along the outside
of the board, and then call cairo_clip. Then you just pass that cairo
target to the normal rendering routines and nothing will be drawn
outside of the board edges. You may have to review the gerbv code and
figure out which translation "frame" to draw the edge in, though (the
current transform matrix will have to be zoomed in to the correct level,
etc). I think that will give you the appearance you desire.
Julian
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