Well, I took a step backwards. The monobloc cell carrier and switch mount design was a problem as I previously explained. So, now there will be a two piece block. A small piece for the switch mounting and a larger piece for the cell. I also changed the cell that will be used. I will explain as I go along.
First, the switch mount change. I made switched from softwood (pine) to a hard maple hardwood. I cut and routed two pieces with slightly different total thickness to see what would work best.
The change to a two piece block means a different method must be used to hold all the pieces together. That begins with the need to drill a hole in the copper heatsink plate, for a machine screw. The spacing of the fins required removing a part of a couple of fins.
Here’s where the hole is positioned. A 2-56 machine screw is to be used. This is the smallest size screw I like to work with. The head of even the smallest style screw head is too large to fit between fins. I did not want the screw head to protrude above the upper surface of the heatsink.
I used a Dremel tool and a steel cutter bit. The heatsink was securely clamped in the bench vice. I hand held the Dremel tool, quite firmly and with both elbows braced and supported on the bench. With a certain amount of trepidation I removed copper a fraction of a millimeter at a time. Mostly it went pretty good, though the recess ended up larger than intended due to a slip or two.
The hard maple switch mount plate was next. One of the strips I cut and routed was ripped to a narrower size; the same width as the heatsink. The front end rounded to fit the curve at the front end.
The next picture shows the switch test fitted and then the driver mount fitted/screwed into its place.
The driver was test fitted as well.
More coming in a few minutes