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Hi Everyone, I have to modify this heat sink. It's made out of A6063 and fins are .037" thick and 1.338" tall. I need to cut 3 columns of fins off then in 4 other places along the edges there needs to be some small spot faces for bolts that will require machining 2 fins away at each location. How do you cut fins away without damaging ones around it? my co worker thought slit sawing but sadly with the size constraints of only cutting two fins out without touching those around it doesn't allow for that. My only guess for now would be to maybe slowly ramp down on top of each fin individually with an 1/8" end mill. Or go full depth (which is .004" into the surface the fins come from) and just slowly cut the whole fin away at once. Anyway I am totally at a loss since I have never done this before. Sadly I have no extras so I thought I might seek some expertise here before mangling one and being short for the order right out of the box.
