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I think I'm going to do an aluminum plate instead of a heatsink. I can mill the edges of the plate so that it has extrusions with holes that can be bolted to any old heat sink if you want, or it may not be needed. I think that's a much cleaner and professional (a la curtis, et al) way of doing it. I'm thinking of 3/8" plate. It will also keep the dimensions to a reasonable level. Not everyone could fit a controller that is like 6 or 7 inches tall (counting the heat sink) inside their car! Ben had a terrible time getting version 1 in his car.
I think HaroldinCR is right. All the support will be coming from the base plate, so it wouldn't matter if the sides are thinner. They would be there to keep out the elements, so I bet 18 or 20 gauge would be fine, Hondo. I'll PM you with more exact dimensions.
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