not sure if anyones following along, but if you're interested, thats an outstanding fire button! even if it looks a bit weird on there - its easy to reach or you can prop the right side of the pad on your knee or desktop and really hammer it for maximum firepower.

It's also weird having the differing travel distance and minimum required pressure, but I think that can be something you'd get used to.
Anyway, its a bit redundant to have 2 buttons with an identical function right next to each other.
the next phase of this modification is to add a rotary switch, this will allow me to turn certain buttons on or off, or redirect them for 3 different modes, i'm sure you can guess where on the pad this will be installed.
default: 2 fire buttons + all cd32 functions & fully functional dpad (cd32 functions are all working in all modes)
platformer: up on dpad disabled - re-routed to fire button/J1, arcade button exists as sole fire button. this gives me a row of 3 buttons on the fascia, fire, jump and (if used) J2 - kinda like the old Sega pads.
racing: up and down on dpad disabled, L2 and R2 are always wired to up and down respectively in all modes. should give good results for games that use up and down for gas/brake!
once its all done i'm probably going to spray it all satin white, still interested if anyones got a suggestion for a good paint brand.
btw the attached file shows the wrong switch type - the one i get will be either a 4 pole, 3 way switch or a 3 pole 4 way. maybe there's another combination I could do with that.