Photos are here!
Successful graft attempt. Ugly but meets the design specifications. I'm exploring options to improve it aesthetically.
Precisely 3/8" from board to tip, and 1/64" shorter when depressed.
So where does the magic happen inside? Here's a peek...
This is the second one I opened, the carbon slug is still almost where it should be, but it has slipped just a bit too far into the plastic cone that holds it.
This is how the first one looked when I opened it up.
Here's more or less how the "graft" works out.
In addition to aesthetic improvements I need to select a suitable adhesive to fill the gap here that is non-corrosive, non-conductive, and able to withstand soldering temps at least briefly. Without something holding it together things can get out of kilter when actually installing the units.
Another option I found in my tac-switch drawer would be these guys. They have exactly the necessary lead spacing to be drop-in replacements, but to get everything to line up right they'll need a bit of a shim between them and the board to bring everything up to the required height.
Look for "revision 2.0" coming shortly.
Thanks again to Phil for getting the ball rolling on the whole thing.
