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I haven't seen the Crawford design but something sure sounds wrong to me. First, you have almost the same AC and DC voltage. Every etcher I have used has the DC voltage level at half the AC voltage. That is just naturally what happens if you convert AC to DC voltage without going to a lot of trouble to have it be otherwise. Etchers are too simple for that so it should be more like 24v AC and 12v DC.
Second, far too much time. I have two etchers, depending on the steel either will etch within 15 to 25 seconds. I etch 3s on and 2s off, repeat that cycle 3 to 5 times.
Etchers are so simple that one can be made from nothing more than a 12vac wall wart and a diode. Can't imagine what's wrong with yours but some pics might help ...
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