How hard is it to manufacture a power button?

So over the last couple of days, I have been building a new VMWare server / NAS in my basement.  This involves ordering and assembling probably 50 different components.  One of those components is the case that everything mounts to.  Last night I completed mounting everything in the case, and began testing.  I could not, for the life of me, get this server to turn on.  Since I had assembled everything over a couple day span, I figured I must have missed or forgotten about something.  I start double checking all of my work, and I can’t find anything wrong with it.  Finally, I get frustrated and just short the pins for the power button with a screwdriver.  The server immediately powers on!  WTF?  So I test the power button with an ohmmeter.  It reads about 130ohms.  That means the button sort of works, but isn’t quite completely making a connection.  How the hell does that even happen?  How hard is it to manufacture a power button?

So my options are this:  I either disassemble the entire server and return the case, for a new one (a huge amount of work), I install a secondary power button and stick it to the front of the case (cheese), or I just deal with a server that doesn’t have a power button.  I have the server configured to automatically power-on when it receives power from the wall, but having to unplug the power cord to shutdown the server is not exactly what I had in mind.  What a pain in the ass!

Oh, and to be clear, this is a rackmount case, with a very unique power button.  It’s not something I can just purchase and replace.  What a pain in the ass!