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Isn't it just the opposite? The current ones have no HIS and the ones he'll be adding have them. So he'll be dealing with a thicker part - not a thinner one that needs gap filling. Right? Or did I misunderstand?

I think he's talking about the regulators that surround the CPU. When the CPU is thicker the heat-sink no longer touches them - if indeed it ever did in the 1st place. There was some discussion about this a I recommended a thermal pad. The OP at that time thought it was a great idea and all but I have some questions as to whether or not it's actually needed.

Here: https://forums.macrumors.com/threads/738826/
The info is right, as is your evaluation. :) On the OEM parts Apple's using, the naked CPU and VR's are the same height, and make contact with the copper surface of the heat sink.

Commodity W55xx/W35xx/17-9xx parts have the IHS, and will end up breaking contact with the heat sink and VR's. Using the mechanical drawing Intel provides, the gap will be 1.845 - 1.895 mm. in height that has to be filled.

If you know of a good product that can do the job, it might be helpful. :) The GapPad material I linked has good thermal conductivity, is electrically non conductive, and comes in thicknesses that can do the job without the need for multiple layers of it.

As a price example, I found the 1500 series, in a 4" x 4" sheet, 3.18 mm thick (1.5 W/m-K) @ $20.30USD from DigiKey (here). It could be used, but personally, going through this much hassle, and not sure how hot the VR's are getting (only estimated), I was thinking a better thermal conductivity was in order, and was thinking more along the lines of the 2500 series material. ;)
 
Tutor - how can I hire you?

I'm serious. I, too, am a corporate video editor, and I'd like to hire you to provide (email or phone) consulting as I attempt to build a beast for myself. I'm great with shooting and editing, but tearing apart a mac...not so much.

I know you said it is pretty easy, but I don't have the luxury of time should I make mistakes, etc. Got more client work than I can handle right now and I have to stay focused.

If you would be interested in making some money with your mad skillz, let me know how we can go about making contact.

Nice work, btw, really impressive.

cc
 
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