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Working with Plastics
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Level42:
Hey Selfie, excellent tips, thanks !

Do you have any suggestions for fixing somethiing like this:



It's a button from a Japanese Namco Galaxian cab. These kind of buttons are not available anywhere. I was thinking about trying to sand it down far enough to get an even top again and then go sanding with finer and finer paper and then using my micro-mesh kit.

Alternatively, would it be possible to make something like this brand new ?

selfie:
You might be in trouble there...  I think you will find the burn goes far too deep to be able to sand it out. From the looks of that button it is injection moulded, so it can't be remade the same way without a massive setup cost.

It a bit hard to see form the pic but it should be easy enough to fabricate one out of layers of acrylic. One piece the size of the hole laminated to a piece bigger to stop it falling out of the hole and the a couple of pieces attached on edge to space it out form the switch mech itself.
Le Chuck:
You could do a simple two piece or three piece mold and pour some lucite.  Just prep the original with sanding and bondo so you get a good form to work with.  Probably a solid saturday's worth of work for a small part tho. 
kahlid74:
You could also make that with a 3D printer, some Nylon and a rip roll tumbler.
Level42:
Thanks for the suggestions guys !

I'll have to remove my buttons to give them a closer look before moving on. I really like the idea of 3D printing. The "market" for these is probably just a handful of cabinets around the world so a "one of" solution it has to be. 3D printing files are easily shared and can be printed more or less locally.

I'll also go over to my perspex dealer who also do a lot of work on shaping, drilling etc. (they did my SW cockpit plexi's) Pretty sure it's hard because it's so small, but worth a try.
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