2stageEF high performance class AB power amp / 200W8R / 400W4R

If you find the right black magic marker you can colour the end of the screws black to blend in. Marksalot brand are good for this here. Many others come out purple.

An option to increase thread life in aluminum is to use long set screws as studs and leave them in the heat sinks.
Hi Jeff and Andrew, thanks for the tips.
Do you mean screwing bolts on heatsink and fixing the heatspreaders using washers and nuts?
 
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The drill size for a thread forming tap is bigger than the drill size for a thread cutting tap.
You will need to find out what drill size to use for the material you are working with.
Aluminiums are quite different formulations and I suspect this affects the drill size.
 
Another option is to use a tap that "forms" the threads rather than cuts them.
These work well in Aluminium, no chips and the tap is less likely to break, not weakened by chip clearance slots.
Should be available in your country or easy to send in a plain envelope for mail order.
...

Yes - that's a good alternative to standard screw tapping ...

I will try using this one: gewindebohrer.de - BAER HSSE-TIN Forming Tap M 3 x 0,5 - DIN 371 with oil grooves 34TD70320601
You will need a

  • 2.8mm drill for M3
  • 3.7mm drill for M4
  • 4.65mm drill for M5

BR, Toni
 
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Thread rolling taps are better for sheet metal. In blind holes they are more prone to stick. They do form a tough smooth thread though.

I'm not sure if Sowa will ship to Greece but they have a good selection of aluminum taps and a reasonable priced. SOWA - Homepage

Not those parts some posts ago - especially designed for blind holes.
But one must use oil during forming the tapping ...

BR, Toni
 
Looks like i have another option when the drilling is between fins (no blind holes required).
 

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