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Getting leaf buttons into 1-1/8" metal CP hole?

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Knievel:
Hey QB I've actually had many e-mails on this subject. Almost every person that tries my idea runs into this problem. Looking back I should've brought more attention to the fact that the leaf buttons are bigger than a standard button.

I have worked with leaf buttons on CP's since my Neon Mame and none of them have fit into a 1 1/8" hole, in MDF. Some people here seem to disagree so they must have different buttons than me..and you. Possibly they are non-wico or an older style as I buy nothing but new buttons, directly from Wico.

Anyway what you were asking for was a solution, I suggest a sanding drum that is inflatable. You insert it into the hole, pump it up, and sand away. I think mine was about $30 though so you'll probably just want to go at those holes with a hand file as suggested. I'd be happy to ream them out for you if you want to ship the CP to me.

whammoed:
Not that its needed, but I got some leaf buttons in from Bob Roberts and I happen to have both a 1 1/8 and a 1 3/16 greenlee punch.  This means I can test on the exact size holes with no paint or powder coat to change the diameter.
Results:
First pic shows both holes.  The button definitely won't fix in the 1 1/8 hole, but not by much.  Less than a 1/32 and it would go (except for the security tabs.)  Button won't fully seat in a 1 3/16 hole until you file out the triangles for the security tabs shown in second pic.(they don't need to be that big)
In the future I will always cut a 1 3/16 hole in metal even if I don't plan on using leaf.  The microswitch buttons still fit fine in the larger hole and it keeps your options easily open.

Hope this helps in some way.

BTW, leaf buttons rock.  I had forgotten how a button should feel.  I hope those leaf mods for the microswitch buttons ponyboy has feel like these do.

quarterback:
Thanks for the post, and the pics, whammoed.   I was intrigued by the "greenlee punch" you mentioned and thought "Hmmm.. maybe I should get one of those!"..... and then I saw the price  :o    A little pricey for my couple CPs :)

I'll be interested in hearing the first reviews of the new ponyboy leafs.

whammoed:

--- Quote from: quarterback on February 09, 2006, 01:38:56 am ---Thanks for the post, and the pics, whammoed.   I was intrigued by the "greenlee punch" you mentioned and thought "Hmmm.. maybe I should get one of those!"..... and then I saw the price  :o    A little pricey for my couple CPs :)

I'll be interested in hearing the first reviews of the new ponyboy leafs.

--- End quote ---

They are pricey new, but since they pretty much last forever, get them on ebay.  I have paid anywhere from $8 to $20 for them.  They make really nice holes with no burs to file down.

quarterback:

--- Quote from: whammoed on February 09, 2006, 09:11:40 am ---hey are pricey new, but since they pretty much last forever, get them on ebay.  I have paid anywhere from $8 to $20 for them.  They make really nice holes with no burs to file down.
--- End quote ---

Just to make sure, I'm looking for something that looks like this



More than something like this



Is that correct?
Thanks w'

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