Cool fairmana, thanks a million. Now I think its time to get it ordered. The misfires are becoming annoying. I was looking at this switch its blue- sw800-nd , 10 million rating but only 130 gf , sounds like it would fire too easily if I set it down ... Better go with the 350 gf yellow one Sw976-nd .... So it says 4.3 mm, but it mounts to 5 surface mounted. That's no an issue I figured those tabs could be bent.. Did you take the whole nub off to flush?
Jeremy, my thoughts exactly. That's pretty much been my headache from the start. All the switches that boast a high lifespan (> 1 million presses) all seem to be rated at around 150gf of operating force to press them (too soft). This is the first time I've been able to find a switch with 350gf while at the same time having a lifespan of at least 1 million presses.
Your right, the B3F-5000 you mentioned (SW800-ND) is rated at 130gf, but another problem is that it isn't a sealed switch either. The B3F-4055 in the B3F series would be a better choice at 260gf and 1,000,000 operations, but again this series isn't sealed and 260gf is still too low. Based on what I'm feeling from the B3W-4005, anything lower than 350gf would be too low IMO. The other switch I bought (B3W-4000) is physically the same size switch and boasts a 3 million press lifespan, but unfortunately has a 200gf of operating force. I bought 2 of these but 200gf still feels too soft. Anyone could use the softer switches with success and be sure of a very long lifespan if they could live with that soft touch required to fire it.
To answer your other question about the nubs, the B3W-4005 switch body is 4.30 mm so I had to sand the nubs on the bottom until they were about 0.70 mm long (5mm total). I just opened the jaws of my micrometer to 5mm and sanded the nubs until the switch could enter the micrometer jaws sideways (do both nubs individually). I used medium grit sandpaper, and it didn't take very many swipes to rub them down. Try to apply even gentle pressure while holding the switch level as you sand it (not easy) so both nubs are sanded evenly. Stop and check your measurements after a few swipes on the sandpaper so you don't sand them too short.
You'll have to bend the legs off to the side to where you want them before you can sand the nubs since the legs are in the way. What I did first is take a nice pair of needle-nosed pliers with a fine-toothed jaw, and straighten the lower half of the legs so they came out of the switch and went straight down at a 90 degree angle. Then I grabbed both legs with the pliers just below the switch so that I could see just shy of 1mm of air gap between the switch and the edge of the plier jaws. I tried to keep the edge of the pliers parallel to the switch body so both legs were bent as close to the same length as possible. Then I made my 90 degree bend away from the switch while trying to keep the upper part of the legs from moving away from the switch body. I have yet to get my bends exactly where I wanted them, but it's not terribly critical so long as the bends don't make the switch set too high off the board or too short to be soldered. In other words, it's better that the legs be bent a hair short so you can angle them downward later to make up the difference whereas if the bend is too long, you have no leeway to make corrections and will have to straighten and re-bend them. If you have to straighten out any leg to start over, go in small steps and very slowly. I was paranoid that I would snap off a leg if I bent it too fast. They are probably sturdier than that, but why chance it.
The plastic nubs on the underside sit across the center of the switch, so if the legs are too short, the switch will rock toward one pair of legs or the other and not be level. You may need to make adjustments or re-bend the legs until the switch is about level on a flat surface. The 5mm gap in the jaws of my micrometer came in handy here as well. Once I cut my legs to length, I had to make 1 or 2 fine adjustments and slightly angle my bends downward so that the entire switch sat level on my desk on the sanded nubs and all 4 legs (or very close).
The main pressure when you push on the button should fall on the plastic nubs, but once the legs are soldered they should also be able to provide good support. I removed all the excess solder from the circuit board pads with a solder wick so none of the legs would be forced to sit high. I also recommend you use a small amount of flux on the pads and the legs so solder flows well to fill any slight angled gap under the feet. I held the switch in position with firm pressure with my finger while soldering so it wouldn't move out of position. I also used just a hair more solder than you would normally expect to see on a surface mount component just to be sure they would be good and strong. Don't forget to clean up the flux with alcohol and a small brush afterwards.
One final thing which is purely aesthetic and nit picky... If you want your switch to be nicely centered under the plastic window, check your board inside the tube first and decide if the switch should be soldered further forward or backward on the board. My switch appears a bit toward the screen and if I had checked it before soldering, I probably could have soldered it further back on the board. There's a little leeway where you can solder the switch since the pads are about twice as wide as the switch feet. Just be careful since there might be some other contacts on the board close to those feet (electrical short).
Best of luck and sorry this was so long winded!
Here's a pic of the before and after. You can see I haven't clipped the leads to length yet.
