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The original idea for this sink was to work out a way to run dual TEC's on a air cooled heat sink.  In the playing I did with the Alpha P125, I came across a couple of things that prevented that otherwise great sink from filling my needs.  One was that the base of the sink is not a single flat plane.  There is a step in the center of the sink where it meets the slug of the processor package.  While I understand that this was probably done to allow it to fit the PII with its cache modules, it wasn't suitable for mounting 2 TEC's side by side.  When I machined the base flat on one of my Alphas, the result was a base that was too thin to carry the heat to the outside fins.  Adding a hot plate to the base was fine, but the fact that you end up with two large surfaces to try and mate perfectly doesn't work.  You end up loosing most of the performance you gain in mass due to the poor fit between the two pieces.  No matter how carefully machined the surfaces are, the performance won't match a single piece base.  So after some thought, the aluminum and copper sink idea was born.  I played around with the idea until I finally drew up the goal for the project in AutoCad.

The original idea.  Notice that there are a lot more pins on this than on the finished product. 

Because I was trying to do the work with tools not ideally suited for this project (as usual), I made some concessions and decided to make the first sink a little less of an ambitious project.  Instead of the original 420 pins, I would scale it back to 240.  There was also the problem of actually fitting two 40mm TEC's between the holes used to mount the Celeron.  They don't fit, so you either switch to 30mm TEC's or don't allow the mounting screws to go all of the way through to the heat sink.  I chose to go with one 40mm TEC for the first attempt and see how that would work.

Once I had a working model running without the aid of a peltier, the switch to adding a TEC was pretty painless.  I used the small machined copper cold plate and the Celeron insulation I had used in a couple other projects.  I did need to add some new insulation to the cold plate and between the Celeron and the sink.

The TEC and cold plate are added.  The insulation is from the
local home center and comes in 4 X 8 foot sheets.  The
yellow strips are double-sided tape.  The screws for the cold 
plate are made of less thermally conductive nylon.

With only one peltier, I didn't expect that the temperatures would fall much below 0° F at idle, but that was more than cold enough to produce plenty of condensation.  I had been through enough condensation recently and was hoping that this insulation would be enough to stop the drips on to my Matrox AGP card.  I was darn tired of unexpected resolution changes.  It's probably not too good for the card either ;-)

A good thermal paste pattern, and a tight fit for the assembly studs.

With all of the pieces of foam in place and sealed with silicone sealer, it looks pretty tight.  Measuring the depth of how far the slug will protrude into the foam to contact the cold plate seems like it would be easy enough, but it took a few tries until I got a good pattern of thermal grease between the slug and the cold plate - and - no air gaps between the cold plate's insulation and the Celeron's insulation.

The pieces are assembled.  If you look to the left and right edges, you can see the insulation for the Celeron.  It's a little on the worn side after being on no less than six different sinks before this one.  One of these days I'll get around to replacing it.

Now the top side of the Celeron's insulation is visible.  As you can see, this is no assembly for a compact sized motherboard.  The fans are set to draw air through the fins, rather than to blow air on them.  If you're wondering about the notch on the fan shroud, that was for some sensor wires on another application.

The back side.
Performance specs  ==>

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