Favorite method for shaping/cutting stock heatsink?

[Mooper]

Anyone got any any tips or tricks for removing some of the fins on the inside of the heatsink without mangling the rest of it?

 

[Fluxedo]

CNC is preferable lol. Or use one of the small cylindrical dremel bit and do it vertically and then use a small cutting wheel bit once you get a few rows of fins off horizontally and then get it smooth with the top of the cylindrical bit. After that sand the whole thing down with a electric sander to get it to your desired height

 

[Mooper]

That's more or less what I did last time. I was just hoping there was a cleaner way short of using a milling machine. I bought a tungsten carbide bit for my dremel today, but it wasn't very useful.

 

[E64]

Try using a diamond cut wheel