I disassembled my DC-30 when the on off switch quit working. The switch is a very small button unit soldered with three leads onto the main board of the DC-30. Mine fell off and was rattling around in the case. My soldering skills are not up to remounting the button, nor did I want to solder tiny wires to the main board. I'm sure there are some guys that can do it.

I ran into Chris (Forgot his last name..) who said his button broke too.

It isn't and on/off switch, just a quick connect that momentarily completes a circuit. Power is to the middle of the three leads. I found you can turn on the system by quickly jumping these leads with a scalpel blade or turn it off by holding the connection for a few seconds, much like the button operated.

I since disassembled the DC-30 by leaving the main board in place, moving the battery in-line behind it, bolting/epoxying the pieces to a piece of G-10 and disconnecting the power charger. I use the club's patented 30 G electrical tape to secure and cover the otherwise open to the air circuitry. (If I could figure how to upload a picture here...)

So now I have FrankenGarmin. I have to reconnect the charger to the battery to charge it, jump the on/off connections manually, and more carefully treat it since I removed most of the case.

It now fits into 38mm tubing. I'll give it a try next launch.