Just noticed this thread.
I used the Altoids mint tin and changed the battery holder from two batteries to three. I used this holder from Fry's.
http://www.frys.com/search?search_type=regular&sqxts=1&query_string=3+aa+battery+holder&submit.x=0&submit.y=0&cat=0



I also used a hot glue gun to secure the battery holder to the tin. It was wobbling with only the double backed foam under it.
Edit: just worked out the benefits of 3 batteries versus 2. From here,
http://www.ladyada.net/make/mintyboost/power.htmlFor 3 batteries,
mintyboost mWh = Battery voltage (V) * Battery capacity (mAh) * Capacity derating
3 * 1.27 V * 2500 mA * 75% = 7144 mWh
Output mAh @ 5V = Battery mWh (mWh)/ 5 (V) * Boost Efficiency
7144 mWh / 5V * 80% = 1143 mAh output
# of full recharges = MB output mAh /Device Battery Capacity
1140 mAh / 1420 mAh = 0.80 times (iPhone 4)
For 2 batteries,
mintyboost mWh = Battery voltage (V) * Battery capacity (mAh) * Capacity derating
2* 1.27 V * 2500 mA * 75% = 4763 mWh
Output mAh @ 5V = Battery mWh (mWh)/ 5 (V) * Boost Efficiency
5060 mWh / 5V * 80% = 762 mAh output
# of full recharges = MB output mAh /Device Battery Capacity
762 mAh / 1420 mAh = 0.54 times (iPhone 4)
So, 3 batteries is (0.80/0.5) = 1.48 x better than 2 batteries.
Edit 2: Just worked out that I could have possibly squeezed 4 x AA battery holder in the tin. Might have to order another MintyBoost ... :wink:
For 4 batteries,
mintyboost mWh = Battery voltage (V) * Battery capacity (mAh) * Capacity derating
4* 1.27 V * 2500 mA * 75% = 9525 mWh
Output mAh @ 5V = Battery mWh (mWh)/ 5 (V) * Boost Efficiency
9525 mWh / 5V * 80% = 1524 mAh output
# of full recharges = MB output mAh /Device Battery Capacity
1524 mAh / 1420 mAh = 1.07 times (iPhone 4)
Cheers
Andrew