Paul,

Just for the heck of it, you might want to check out these heat sink
extrusion wholesalers for possible applicable profiles. They might be
able to suggest a solution without a lot of costly machining.

http://www.mmmetals.com/pages/extrusion_profiles/aluminum_extrusion_profiles.htm

http://www.accelthermal.com/index.php?page_id=104

http://www.alphanovatech.com/?gclid=CN7fvczZlacCFQQFbAodsHqgcA

Regards,


Jack Hilditch

We are using the mmmetals. They are about $10 a foot as I recall.

Paul Lamar