How to cut large heatsinks?

[bobgroger]

I have 2 heat sink extrusions measuring 5X8X25 inches. I would like to cut each one to 6" lengths. Can this be done reasonably accurately in a DIY fashion, or should I find a machine shop? What would a reasonable price be per cut?

Bob G.

[herm]

I did a thread on cutting aluminum.

Here's the link:

Cutting Aluminum Thread

If you have experience with power tools, its fairly do-able.
If you don't I wouldn't recommend it.

Sorry about all the drama in that thread


herm

[krazatchu]

Those are large pieces... in metric 12.7 x 20.32 x 63.5cm...

I would use a chop-saw or a bandsaw with a metal blade...

Perhaps there is a local junkyard/salvage yard... where they might have a chopsaw...

Wouldn't take more than a few minutes and shouldn't cost much...

You could also try a highschool, if they have tech classes you could get a student to do it...

[Minion]

I used a Chop saw to cut a 12 in x 10 in Heatsink into 3 Parts, It was hard to get a proper straight edge when cutting but was able to grind the edges smooth with a grinding tool...Didn"t take long and was pretty easy...I suggest you put the Heatsink in a stable vice before attempting to cut....

Cheers

[bobgroger]

Originally posted by herm
I did a thread on cutting aluminum.

Here's the link:

Cutting Aluminum Thread

If you have experience with power tools, its fairly do-able.
If you don't I wouldn't recommend it.

Sorry about all the drama in that thread


herm

Thanks, lots of good info there.

Bob G.

[cuibono]

I didn't read the above thread, so I might be repeating, but I've cut heatsinks with:

a hack saw - works well, but maybe slow, and doesn't cut deeper than a few inches.

a masonry blade, in a table saw: worked quickly, straight cut, danger from sparks + sawdust. I assume you could put the blade in a circular saw too, but you've got to clamp it real well. I'd bet a diamond blade for cutting tile might work too.

I've even used a regular hand saw (for wood) one night when I was desperate. A reciprocating saw with a metal blade would work too..

[poynton]

I used a tile cutting saw with a diamond disk


Andy

[quasi]

If you have access to a mill, this is how I cut mine.

The large heatsink was clamped to a heavy angle bracket which was bolted to the mill table. Nice and slow but dead accurate. Note the use of lubrication during the cut.

Cheers
Quasi