Phil,
I confess, I like your first suggestion of taking the picture of the old radio and superimposing it upon the replacement aftermarket unit. I could have the best of both worlds: that "classic" look combined with up to date technology.
Here is an ironic update. Yesterday, I got into my 850 and pushed the "On/Off" and my SC-815 radio and it worked! There is no rhythm or reason to it. I had done nothing to it. It just worked! The button is still "broken" in that doesn't possess the natural "tension" to the touch. The button is "loose" in the slot. I think you might be onto something about cleaning the area around the button to remove some dirt or "gunk" that has collected around it. I'll try that.
Of course a form of "Murphy's Law" kicked in. What I mean by that, is the radio "fixed" itself only AFTER I ordered a used radio that had been shipped to me and was in transit. The salvage yard said I could "refuse" acceptance of the package and it would eventually be returned. I have a good relationship with this salvage yard, and I don't wont to come off as a "Jerk", so I told them I would accept the radio. The price was not huge ($65), plus my radio could stop working again tomorrow. Miracles come and go. Also, I have another 1996 850 GLT wagon, also equipped with a SC-815 radio and it could go on the fritz tomorrow too. I have spare SC-815 radio today, that may not be the case a few years from now. Like real estate, they don't make them anymore.
But I think your suggestion of gently cleaning the button of my radio has worth. So thank you for sharing your advice and humor. Your help is reflection of why I value this Volvo community so much.
Hugh
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