Hi,
Most of us here have certain kinds/colors/materials of buttons that
are grosser to us than others. In fact, some don't bother me at all,
and others make me physically sick.
If you couldn't take off the buttons to sew it up or replace them with
snaps, maybe you could see about replacing the buttons with a
different kind of button? Even a slight difference in a button (at
least to me) can sometimes make a big difference in its "gross factor."
As far as the other kids go, I would say that a little white lie
wouldn't hurt. He could tell them he was allergic to a certain kind of
plastic or something. :) He should NOT tell them about the phobia
because they will taunt him with buttons and there is NOTHING worse
than that.
~Lisa