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This one failed just slightly beyond the duration of its one-year warranty
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Grab diagonally opposing corners in a bench vise and slowly increase the clamping force until the case snaps apart.
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A quartet of 5/16-inch lathe bits provided the right spacing to hold the heatsink over its new flanges while the epoxy filled in all the gaps and irregularities.
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Y’know how some folks say they don’t wear a seat belt because they want to be thrown free in a crash?
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The solder blob on the other side looked just fine, but you simply can’t tell by looking.
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Turns out that the rear brakes on a Tour Easy are backwards from their orientation on an upright bike
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Of course, it broke at the first pedal stroke while pushing off across an intersection, which is why I never try to ace out oncoming cars.
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Assuming a max heater ambient of 150 °F = 65 °C, you can use 84% of full power.
The Smell of Molten Projects in the Morning 