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Adding heatsink with electrical isolation
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EEEnthusiast:
Thank you all for the great inputs.. I would try out these and let you know which one worked the best in this "case".
BravoV:

--- Quote from: andy3055 on December 12, 2019, 02:09:28 am ---Rather than complicating the process by precision engineering the “heat exchange” type h/sinks, why not mount the transistor (with proper electrical insulation-I would use mica/plastic washer/thermal compound) in a convenient position that does not interfere with the PCB and have the leads soldered to 3 wires that end up in a plug? This is a common practice in a lot of things. Examples can be seen in most Tek scopes. As long as you have a tight fitting plug, I don’t see any issue.

See attached image where you can see the transistor on the left of the EHT transformer on a 465M scope.

--- End quote ---

Not possible as the case style is where the PCB slide in type thru front / rear openings.
EEEnthusiast:
I would rather use a case which has a top side open access. Let me not compromise the thermal integrity over aesthetics. This would enable me to mount the TO-220 on the TOP lid and connect that to the PCB using wires.
BravoV:
Instead of this kind of style ...




Why not just use this below 2 pieces splitted extrusion style enclosure, your problem will be solved nicely.

EEEnthusiast:
Thanks, I was going to use that same one you recommend...
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