Are there Dremel attachment(s) meant for removing or shaping solid aluminum?

First, I'll explain the background for my question.  I've been meaning to make a 1000 lumen Maglite (Jayrob from CandlePowerForums conceived the design-look it up, it's awesome).  I can get the heatsink from CPF vendors but they come with a 14.5mm diameter pedestal.  I want to reduce the diameter of the pedestal, ideally to less than 12.5mm in order to use a reflector with a smaller hole.

So, which Dremel rotary tool attachment(s) would be appropriate for removing and/or 'shaping' aluminum?  Any ideas, other suggestions, or musings? 


Picture of Are there Dremel attachment(s) meant for removing or shaping solid aluminum?
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Burf5 years ago
Use the steel cutting bits, they come in various configurations. Keep the bit and the piece being worked well lubricated with a light machine to help prevent the bit from clogging with the aluminum shavings. Check the bit frequently and clean out any particles stuck in the bit with a pin or small awl.
Take your time and don't get too aggressive when shaping the aluminum.
Burf Burf5 years ago
That should read "light machine oil".
iceng Burf5 years ago
soft Al smears the metal bit or file.
frollard iceng5 years ago
I recall adding chalk to files to prevent the chaff from sticking too badly...similar couldn't hurt on the cutting tool.
We find the best lubricant for aluminium cutting is a solution of clean engine oil and "white spirit"- which is a paint thinner.

OmniWrench8000 (author)  steveastrouk5 years ago
Thanks to all for the helpful info. It will be a few weeks before the driver and emitter come in from Australia so I'll take my time and do this the right way.