Here are the files for the Battery Charger. I tried to clean them up some and make it more readable (it's not perfect), however some errors may have been introduced in the process. Also some of the parts have been changed throughout the course of this project, but if they had the same footprint I didn't bother changing them in the schematic Often there are several parts you could use, the only one that matters is the temperature sensors. If you open up the schematic in Eagle and click on the temperature sensor it will say it is the LM62, but in the final design I ended up using the TC1047A. This makes a difference in the firmware because the TC1047A has a Temperature Slope of 10mV/°C, whereas the LM62 has a Temperature Slope of 15.6mV/°C. Other than that if you use the part listed you will be fine (or you can pick your own parts).
A manual is being put together for the latest version of the firmware and I am making a tutorial to show you how to upload it for those who need it. I am also working on a dedicated page for this charger on my website so that all the info is not just buried in my blog.
I didn't have the right screws (they were not long enough) but I still wanted to put some pictures up so I just set the case on top of the standoffs. I had the cases cut locally and they did a great job, especially when you considering I had them use acrylic that was 1/4" thick.
If you take advantage of the LED pad on the bottom, then the case does a great job of coupling the light out to the edge.
I did an experimental test to see how the charger handled charging a single cell at 2 Amp's. I had to power the board from a power supply through the unmarked pad next to the USB connector. This bypasses the polyfuse and allowed me to achieve the full 2A charge current. The end result was a fully charged 2200mAh battery in just barely over 80min (the scale at the bottom is in seconds). The 100uH inductor (some of the images show a 270uH inductor, but the final is 100uH) got up to 55°C and the battery ended at 39.8°C. I would say this is pretty much the most current I would want to run this charger at. In general I would stick to a maximum of 1Amp (or close to that).