Something else to be aware of on the Double Quadro XL boards. The silk screened numbers on the boards are incorrect - at least they are incorrect on mine. I have a 1.02d board. The controller labeled "4" actually spins motor 8, and the controller labeled "8" actually spins motor 4. This is just a labeling issue and not an electronics or configuration issue.
I can't see an issue with drilling it out especially if you step up the drill bits by starting small and going bigger.
Chris @ QC Support said that they have seen this before. According to him, the heatsink actually "Floats" and that for small distances like this I can use a small round tool to gently wiggle it back into place. Good news for myself and others if it works. I hadn't seen this suggestion on the forums. Will let you know. -m
Mike: As far as the inward facing surfaces are concerned, you raise a valid point. The only thing you might consider is masking off the connectors that might otherwise get sprayed and then try to spray the conformal acrylic in through the gap between the boards. However, the misalignment of the heat sinks makes that board set a candidate for return -- that's pretty obviously a manufacturing error. Is Holger aware that you have this board-set issue? EDIT: Well, it could be that the "wiggle the heat sink" strategy will work.... Andy.
I am now a certified heat sink wiggle technician. Given the rigidity of this board, I would have wagered against it, however, my mighty 2mm probe shifted the cooling board and now everything lines up just fine. huh. We learn something new every day. -m
Do you get a hat with that written on it? The message is, I think, that sometimes brute force does actually work. Andy.