I'm looking to expand my experience with boost and buck converters both, the TPS61202 looks interesting. Are you hand assembling? How tough is it to solder that package, and are you soldering the thermal pad?
When I got this set of PCBs back from the fab, I found every excuse for the first three days to not start. I honestly was terrified at soldering the TPS61202.
I always hand-assemble my boards, though I have used a hot-plate before.
But I ended up using an Aoyue hot-air rework station and solder paste to handle just the TPS61202, then I hand-assembled the rest of the board.
It worked the first time even. Ok, the boost converter did. I got the wrong LDO and had to swap it, but otherwise the board was fine - especially for "Revision A".
I probably should add that the guys in the UK and Australia doing HAB work have been using boost converters for some time (see http://ava.upuaut.net/?p=353
) so I got a lot of help from them (thanks M0UPU and VK5QI!)
I hope this helps,
PS I have to double-check the test data but I believe we are at 22hrs and counting (battery voltage is still at 2.59v). Those "ultimate lithium" batteries are expensive but when compared to generic "big-box" store batteries they run much longer (I got 7hrs off of 2xAA "Kirkland" batteries) and weigh almost 1/2 as much (15g vs 25g).