Maybe offer heatsink upgrade packages, with little packs of thermal paste.
Also make sure you use ceramic thermal paste (white stuff) not the silver stuff. Newer ceramic paste is better anyways, and far cheaper.
I did just think of 1 other option but it's not an easy on/off deal. Thermal tape.
I had some left over thermal tape from the PC Memory modules, i purchased 3rd party heat spreaders for, and it came with thermal tape. Keep in mind this stuff holds strong and doesn't come off easily or cleanly.
Using longer screws is the best bet,and is what i did.
Maybe BMicro can offer extended screw sets with little washers and nuts.
1 more note, don't use a washer or anything between the heatsink and chassis/frame of your bot. If anything use a tiny bit of thermal paste, it'll cause some of the heat to spread to the bot, and actually use the frame itself as an additional heat spreader. Giving the frame is metal.
Even after 5mins of full speed (about 4.5A) on my roboclaw 2x5, the heatsink and bot frame is barely warm to the touch.
http://blog.basicmicro.com/wp-content/u ... step-2.jpgThe shiny silver square, is where i removed the powder coat and mounted a high amp voltage regulator in a previous bot build. The whole frame was the heatsink for that regulator.
