Oshpark doesn’t seem to like the default gerber file names for the inner layers on a 4-layer board.
The fix is simple:
Rename the file ending in Inner1_Cu.gbr to a .g2l extension.
Rename the file ending in Inner2_Cu.gbr to a .g3l extension.
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Thanks, good to know. I usually keep to 2 layers but 4 layers may be a requirement some day.
Thank you for the info. Don’t need it right now but who knows what I will do next!
I found out (the hard way), that OSHPark cannot accept multiple excellon .DRL files. My boards arrived with only the NPTH holes drilled. 
KiCad generally produces two separate files (project.drl and project-NPTH.drl) for regular and non-plated through holes. The fix is simple. Use GerbV standalone (not the one bundled with KiCad), open both the drill files, and merge them (use FILE > EXPORT > EXCELLON MERGE). Use the single merged file instead of the two separate drill files.
Dan Sheadel from over at OSHPark was awesome enough to not only rework my submitted files (doing the merging bit), but also got another batch of boards sent away for express fabrication.
OSHPark rocks.
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well, the good news is that the current versions of KiCad can merge the PTH and NPTH drl files. There’s a check box for it when creating Drill files in the Plot dialog.
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Ah! If only!.. or am I overlooking the tick box? Or being too timid: I’m using the “old stable” version, for Windows: 2013-07-07 BZR 4022. (I thought that was the most up-to-date RELIABLE version available at 30 Jan 15?)
Seeing your post did make me laugh, though. I’d spent 20 minutes researching complicated answers, not realizing that a simple one will be coming to a computer screen near me soon!
It appeared in 2014 versions only, not available in the 2013…
The Gerber filename extensions used by KiCad aren’t the ones used by most of the low-cost PCB manufacturers. It’s a pain renaming them before submitting the files, so I wrote a small Python script that does that for me. You can find it here.
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