Update: I ripped out the old wiring. I removed superfluous buttons. I received the first of many test LED buttons but there are some issues with getting them seated in the CP. I also decided on a LCD monitor that fit my needs and was within my price range. So the old TV is on it's way out. The Smart Strip is on it's way along with some new wiring and a new PC switch to power on the PC.
I abandoned plans to drill many speaker holes after reading about some sound quality issues and my wife wants me to make this into a juke box as well so the sound needed to be great. The search for good mountable speakers begins.
ButtonsI removed (11) buttons that I felt I would not need anymore.
(4) buttons (2 pair on each side) wired to the optipac serving as L and R mouse buttons. (utter overkill)

(3) buttons hard wired to a modified remote control that used to run the power and volume on the old 27" tv set. With an LCD on the way it was launched.
(4) 7th action buttons from 1-4 players. I will soon remove (2) more buttons from players 3 and 4 as well. I can't think of a reason to have (6) at all 4 players if they are not playing anything but arcade and older console games.

Does a 4-player cab really need all 4 players to have (6) buttons or just players1&2 with (6) and players3&4 with (4) buttons each? I'm not using these controls for anything beyond arcade and early console emulation(NES,Atari, SNES). I'm inclined to think it doesn't. For simple symmetry I can't justify the added expense of extra LED buttons. Not sure if how it will look.
I plan on filling the holes with pieces of wood and wood glue. Towards the end of the project I plan on getting a nice custom overlay to cover it.
There is a row of (10) buttons at the top that I never actually used. They were wired into button #8 on the ipac. I'm not sure how many extra buttons I'm going to need with Hyperspin running the machine. What's buttons will I need besides Esc?
In removing the buttons, I noticed that the holes might not be exactly 1⅛". It took a considerable amount of force to remove them and many of the threads appeared to be smashed.

I received a new test LED button from Paradise arcade. It's not wired but I wanted to see how it felt next to my Happs. I have a used Ultralux on order as well. I'm hoping to test some Electric ICe and Nova gems as, based on what I've seen, I am interested in them the most. They appear to have been sold out for a while now.

As you can see, the button doesn't quite fit into the slot. I am not going to smash these in there. I'm going to try redrilling these holes with a basic set of hole saw drill bits that are on order. I'm using them to make make speaker and power button holes in the cab. The set does have a 1⅛" bit. I'm hoping it's as simple as running that bit slowly and evenly through the existing holes edge. Worst case I get a new control top. I'd like to avoid that though. $$$
Here is the inside all cleaned out. There is a superficial gouge under player 1's buttons. It was there originally and never affected game play or how the buttons sat.
LCD monitorAfter a lengthy search and this reading this thread
http://forum.arcadecontrols.com/index.php?topic=112940.0I settled on a Hanns G that was sale on Newegg.com.
It's widescreen dimensions allow for some of the Bezel artwork to be displayed. After working on the computer on a 23" lcd I found it incredibly hard to work on it looking at a 27" crt television set.

1080P support, 1920x1200 panel, which is 16:10. It is also 27.5".