tx101, did you get my email? never heard back from ya.
Here's an update on what I've been working on.
The original LS20.1 heatsinks were aluminum and a pretty basic design that added a lot more mass than the stock heatsink and also more contact area to the head to improve heat transfer.
After much thought and a redesign, a new improved version was made from brass.
It's a huge step in the right direction for thermal management when running a HO GDuP driver to the emitters.
The brass slug is "stepped" in 3 places and has a tight fit to further help transfer that heat to the head. After turning the slug to its final size, it's seated in a special holder I made for the milling maching to have the holes drilled and pockets milled for the emitters and wires. Another holder was made to secure the brass finish rings so they can have their holes milled and the backside milled for wire clearance for the XM-L.
I feel much better about the new design even though it takes WAY more time to make than the simple design I previously used in my personal light.
About the only improvement I can see from here on out is a way to heatsink the drivers and make the drive assembly
and LED heatsink plug into each other for ease of assembly/disassembly.
Anyway, heres a few pics.