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Discussion Starter · #1 ·
I've decided to screw some new LED's onto aluminum barstock.
Most LED heatsinks you buy have 2 small screws, metric I assume..

Well I have a 2-56 tap and some #50 drill bits so I can drill and tap al I want using 2-56 screws which are a thinner shaft than the ones w/ the heat sinks but head is the same size so no problem there.
I looked for nylon washers to isolate the head from the LED base but I haven't had any luck w/ that yet..

One thing I found is nylon screws w/ a thermal rating of up to 150-ish F

Also found stainless steel..
The ones I have I assume are zinc plated..

Question is : Is any better than the others?.. In the high moisture env. and warmth of the LED's (My non-fan cooled can reach 120F on certain parts of the aluminum.. )..

Feelings about galv. corrosion w/ zinc and aluminum..

To make this really dull thread a bit more exciting.. anyone have any feelings re: using anodized vs non-anodized aluminum?
 

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Pixel Prestidigitator
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Stainless for the win.
 

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Pixel Prestidigitator
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Think how nice it would look with polished stainless instead of aluminum.
 

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When I use screws to hold LEDs I use #4-40 screws, and they are still small enough that it generally takes a couple of taps to get through all of the holes. I would never even consider #2 screws for anything. I haven't tried, nor have I seen #4-40 nylon screws, but I would certainly use them if they are easy to buy. It doesn't take much to hold a LED in place, and those screws would eliminate the possibility of shorting out a LED.
 

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When I use screws to hold LEDs I use #4-40 screws, and they are still small enough that it generally takes a couple of taps to get through all of the holes. I would never even consider #2 screws for anything. I haven't tried, nor have I seen #4-40 nylon screws, but I would certainly use them if they are easy to buy. It doesn't take much to hold a LED in place, and those screws would eliminate the possibility of shorting out a LED.
X2. 4-40s are as small as I will go. Pretty easy to snap a tap off, even in aluminum. So buy two... when you break the first one, you will be more careful with the second! :)

Think how nice it would look with polished stainless instead of aluminum.
Are you referring to the bar stock?
Stainless has horrible heat transfer numbers compared to aluminum.

http://www.engineeringtoolbox.com/thermal-conductivity-d_429.html

It weighs 3 times as much also.
 

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Discussion Starter · #8 ·
X2. 4-40s are as small as I will go. Pretty easy to snap a tap off, even in aluminum. So buy two... when you break the first one, you will be more careful with the second! :)
Screws that come w/ some star puck heat sinks are about a 3......
 
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