Bumping this thread from the dead. I want to freshen up my prototype host that is using an unknown bin XR-E. I bought an XR-E R2 to replace it, but decided to give the XP-E2 a shot. I want to push this thing hard, so I'm going to try my hand at reflowing directly to copper.
Now that I have my own lathe, I'll be able to create whatever heatsink I want. I want to get your opinions on this idea. I was thinking of buying copper rod, maybe 1/4". I'll machine the heatsink out of aluminum, then center drill a hole where the copper rod can be pressed in as well as soldered in leaving it so that the copper post is slightly raised above the aluminum heatsink. I'll sand down the contact points on the LED, reflow onto the copper post, then wire the LED.
Would this give me a good enough thermal transfer? I won't be as good as Match's reflow onto copper, but I wanted to make this as simple as possible.