Replace Low Voltage Bi-Pin Halogens with LEDs

Step 2 Drill the heat sink

The first step is to drill three holes in the heat sink that match up with three of the six slots on the LED star board. The star board is made of a special thermal sandwich that allows heat the move out of the LED die and into the board and then heat sink with minimum resistance (and thus delta T). The back of the star is metal but not electrically connected to the LEDs and must make solid thermal contact with the heat sink. So take your star and place it on the heat sink and eyeball its location and then make three marks in the notches around the star to mark where you will drill your holes. Then remove the star and drill your holes and then tap them so that you can thread the screws directly into the heat sink. If you don't have the tools or wherewithal to tap the holes, just drill them large enough to let the screws slide through the heat sink and use nuts on the backside to hold the star down. See the pics for clarification.