How difficult/easy is it to drill/tap aluminum heatsinks?

[flexy]

I am posting this here.

I am thinking of getting some big aluminum heatsinks to mount LEDs on it.

The problem is I'd need to drill holes and tap the heat-sinks to be able to put screws in there.

I saw some videos and learned that it is possible using a normal (corded) drill and then hand-threading the treads with thread cutters. I do not own a drill-press/bench.

I know there are complete sets with cutter inserts and manual thread cutters available.

How easy is it to drill holes and then cut the threads..or should I have that done by some professionals? (Otherwise I don't have a problem with DIY, I just never did metal-work, hole cutting etc.. obviously I don't want to screw up the heatsinks)

 

[Mr Evil]

Aluminium is soft, making very easy to drill holes in. Drilling and tapping straight holes by hand is a little harder, but still very possible.

A tip: Aluminium will deform into a rasied ridge around the hole when you tap it, making it difficult to clamp something completely flat against the heatsink. You can stop that from being a problem by slightly countersinking the hole before tapping it.

 

[bonehead123]

Drilling holes into aluminum is quite easy since it is so soft.
However, drilling them correctly is more difficult.

I would suggest you buy some small aluminum stock pieces to practice on before you attempt your actual drill & tap operation.

Go slow and be patient

 

[MrTeal]

As others have said, it's not terribly difficult. Cutting fluid is still needed for tapping, and you have to be careful not to snap a 4 or 6 tap. The one thing you have to plan for with a heatsink is to try and avoid having your hole centered on the edge of a fin. If you don't have a really thick base or a bottoming tap it can be really hard to tap a hole like that as the bit will want to bend as it exits the base.