EvilNuff, yeh, even with a pipe cutter, you get a smooth, but not necessarily straight cut.
That's why I suggested a miter/chop saw. With the right blade, if you clamp the button plunger into place, you'll get a perfect 90 cut, no? I just finished building two 4' x 6' pro hockey nets out of PVC and the chop saw made perfect cuts like butter on over 20 pieces.
Ond, it's such a great effect! My desire is to not land an airplane with my control panel, but to illuminate the correct buttons/colors for specific game play while maintaining the look of a desired panel. Honestly, I think white or black buttons would be the two primary options. I think most would desire RGB LEDs for the purpose customizing whatever they want. In my case, I already have my LEDs, so a simple drilled hole to hold them would suffice.
I just picked up ~30 Happ Comp buttons from Crayola as part of a bunch of stuff he was selling in that B.S.T. forum. There are a few colors I don't need, and would gladly donate them to you (or EvilNuff) for the cause of R&D. Certainly the more heads pouring into this, the quicker something can come to either a means to accomplish, or to market for the masses.
Evan