Trim / Squish 2mm off Heatercore
 

I have a heatercore that is 151mm wide and I need it to fit in the width of an optical drive. I'm pretty sure the opening of an optical bay is 149mm max. How can I get the size down? The sides are corrugated, so I thought of trying to flatten the corrugations either with precision hammer blows, or in a vice. I dont think cutting is an option.

Any ideas, tips, warnings?

BFH, then ck for leaks
the outer corrugated plate has no coolant - it supports the fins

The outer edge is ususally corrugated fins. You can flatten them out with a small hammer but I wouldn't use a vice. Sometimes they put a bracket on the sides of the heatercore as a frame support. If thats the case you have to remove the brackets and then flatten the fins, like I had to do.

If you only have to bend it 2mm, just put it in a vise and flatten the edges slightly.

no, do not use a vice - you cannot predict where the collapse will occur
thimk kn

I think you would be better off if you either buy a new rad that is more appropriately sized, place your current rad laying at the bottom of your case or cut the drive cage but even if you are successful in the smash method seems as though you will be creating flow resriction not only for the water but also for air flowing through the rad as all those tiny fins (they are like a little comb and when you smash you will not be able to determine if they smash up or down and they will likely do both filling up the area that was once free flowing for air) are gonna go every which way the same as mine did when the idiots at the radiator place pressure tested the rad at like 80psi or something.

I think I just need to flatten the corrugations on the edges, so it won't make much difference. Even if i crushed the first row of fins it won't make a difference since I need some space to seal my shroud to the rad.

be VERY careful on the ends, you may have to repair them