custombojects.cpp

// All TFC Hud buttons are derived from this one.
// bigguy: replace this line
CommandButton::CommandButton( const char* text,int x,int y,int wide,int tall, bool bNoHighlight, bool bNoBorder) : Button("",x,y,wide,tall)

add this in that func:
	m_bNoBorder = bNoBorder;

paintbackground():

	// Orange Border--bigguy
	if (!m_bNoBorder)
	{
		drawSetColor( Scheme::sc_secondary1 );
		drawOutlinedRect(0,0,_size[0],_size[1]);
	}
teamfortressviewport.h
commandbutton class, public: 

	// bigguy
	bool	m_bNoBorder;
change constructor (first one):
	CommandButton( const char* text,int x,int y,int wide,int tall, bool bNoHighlight = false, bool bNoBorder = false);

classbutton class:
	// bigguy
	ClassButton( int iClass, const char* text,int x,int y,int wide,int tall, bool bNoHighlight ) : CommandButton( text,x,y,wide,tall, bNoHighlight)
	{
		m_iPlayerClass = iClass;
	}
	
	ClassButton( int iClass, const char* text,int x,int y,int wide,int tall, bool bNoHighlight, bool bNoBorder ) : CommandButton( text,x,y,wide,tall, bNoHighlight, bNoBorder)
	{
		m_iPlayerClass = iClass;
	}

then to turn off the borders...
in all the weapons VGUI files, find the creation lines for the buttons and add 'true' to the very end:

ie:
m_pButtons[i] = new ClassButton( i, ""/*sz*/, BORDER_X*2,
ScreenHeight/2 - (i == 0 ? (128 + BORDER_Y * 2):(BORDER_Y * -2)),
256, 128, true, true); <-- add that last true