garnerb350, the board is still good, just no longer good for a joy pad in the original casing (it was the side that the rubber pads touch that I was scratching away on in hopes for copper. At this point I have the analog joysticks off of the board, and it is cleaned up nicely without the left over resin everywhere thanks to q-tips and acetone.
Kowal, excellent pictures. I do not have drill bits that size, and they are hard to find here. My best guess is that you are using about a #39 metric bit. However sitting right next to me is my Swingline stapler, and the staples are the exact size of the holes on the Logitech board (yea for DIY ingenuity). If I can find my fiberglass scraping pen, or make one with an old pen and piece of sand paper I should be able to use the 12 button controller still. I love the idea for the gold header pins, I will have to use that idea on future projects!
I am going to be using wire from a Cat5 cable, once the holes are cleared with the staple, the stripped Cat5 wire fits in fine.