Double Capacity MintyBoost with 4-AA Battery Holder Modification

Step 14 Final assembly

Install the MintyBoost into the Altoids tin as shown. Depending on how tight the USB connector fits through the hole it might be a good idea not to expose the adhesive on the double stick tape until you have the MintyBoost in place. With the USB connector sticking through the hole you can tilt up the circuit board and remove the adhesive protector by grabbing it with needle nose pliers, tweezers or similar tool since there won't be much clearance and then stick it in place.

Now you can add a line of solder along the top of the USB connector joining it to the tin case (second image). This will help to hold the MintyBoost in place while allowing some of the heat it generates to dissipate through the case.

Now expose the adhesive on the battery holder's foam tape. Begin installing the battery holder by inserting the end connected to the MintyBoost (third image) . This will require some gentle prying pressure to get the battery holder started into the case. Continue to slide the battery holder into the case while managing the lay of the power leads (forth image). You want to get the power lead side of the battery case right up against the MintyBoost circuit board. It will require more gentle prying pressure to get the other end of the battery holder into the case. When you do it should snap into place as the curled tin rim of the case snaps over the top of the adjacent battery holder sides (fifth image).

Apply downward pressure to make good contact between the foam tape and the bottom of the case. Squeeze the sides of the Altoids tin to counteract and outward bending that may have resulted from the prying you did to install the battery case.

Comments

[jgillman]

Getting solder onto tin is hard!! Totally worth it though, it dissipates the heat nicely per your suggestion. Thanks!