I think you are taking the right approach. While I had a V5 apart last summer I took a close look at the hole that is bored through the battery tube for the button. If there are some steel burrs left on the inside of this hole they could possibly catch on a plastic button and cause problems. I'm just guessing here. I haven't actually seen this problem or heard of it before. My two V3s have clear smoked plastic buttons. I haven't experienced this problem with them but I have noticed seeing a little white plastic powder appear on the side of these buttons as they broke-in.
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