For cleaning brass, try Cif, works great, and being a household cleaner, it is cheap. Pretty much any abrasive cleaner will work.
Undercutting is a fact of life with photoetching, experiment with various size holes, slots etc. and see what gives the result you're after. Etching from both sides at one cuts down on etching time, and helps reduce undercutting.
You can also purchase brass sheets with photo resist pre-applied. This eliminates the need for cleaning and adding photo resist, but is a bit more expensive.
You can make a photo tool using CAD and a laser printer. If CAD isn't your bag, draw the item by hand, four times the size would be easy for a piece the size you want. Scan it in at a high resolution, and shrink it down in software to the size you want, then print that. Laser printers will not produce a fully black photo tool, you get bits where the black is missing. A trick to overcome this, is to print the item out on two separate clear sheets, overlap and bond them together with superglue. This gives you a true black photo tool. Not sure about inkjet, haven't tried it. If you haven't got a laser printer, you could have the drawing printed at a print shop, but it's likely to cost you more.
If all this sounds like too much hassle, or you don't like to experiment with new techniques, then there are places that will do the photoetching for you. Generally the cost is about £20-30 to produce a phototool (a one -off expense) and then you are looking at about £30 per A4 size sheet. You could get several conning tower decks on an A4 sheet, so if you know others that require this part, then you could split the cost between you.
You will still have to produce the artwork though.