Hiya! Sorry i've been neglecting you - I've had quite a few things on here between family and a friend moving house (from mine! I was putting her up temporarily). All this has been eating my time a lot.
Anyway - I thought I'd at least get you a parts list together, and hopefully a diagram in a couple of days.
Parts List :
1. Altoids tin of the required size.
2. 4 X AA Battery holder OR 8 X AAA Battery holder.
3. 1 x miniature SPDT (Single Pole Double Throw) switch. (for power)
4. 1 x Standard LED in the color of your choice for power on indication.
5. 1 x 180ohm 1/4Watt resistor (for power LED).
6. 1 x USB type A female socket. (for the USB charger)
7. 2 x 150Kohm resistors (only needed of charging apple devices)
8. 2 x 100Kohm resistors (only needed of charging apple devices)
9. 1 x miniature latching push switch (for the torch light)
10. 1 x 5mm High power LED (10,000mcd or higher) for the torch. (your 7000mcd will do, and i've chose the next resistor to suit this LED)
11. 1 x 120ohm 1/4Watt resistor for torch LED (assuming 3.3V forward voltage, and 20mA forward current for the LED - this changes with different LEDs)
12. 1 x small USB hub (2 port will be fine, the smaller the better - it has to fit inside the tin)
13. 1 x USB mini B socket (to the hub) (you are using a type A socket here)
14. 1 x small flash drive (any capacity of your choice - just watch the physical dimensions)
15. 1 x miniature bluetooth or WiFi adapter.
16. 4 x 0.5M of wire in 4 colors - Red, Black, White, Green (this is so you can color-code the power and usb data lines.
17. Some electrical tape (for insulating things)
18. Some heat-shrink sleeving (no necessary, but will help for insulating cables)
next up in a couple of days will be a wiring diagram, and I may be forced into trying to make a video how-to for certain parts of the build - but that will be at least a week away. plus - I don't have an altoids tin, I may substitute a margarine container for demonstration purposes.
I also found out that there should be 4 resistors on the charging port if charging apple devices - these tell the ipod/iphone how much to draw when connected to a charger. I've listed the required resistors in 7. and 8. of the parts list. they will set the charge limit at about 500mA, as batteries will struggle to provide more than that.
Anyway i'll have a diagram in a couple of days, which will cover the batteries, charge port, and torch. The USB hub is essentially a separate circuit, and not connected to the batteries, so i'll detail that separately - and only in a block diagram form. I'll only detail the port connections, as this is the important thing. I've also still to look up the chip, and see if you can ditch components off the hub board - i'll try and have that done for next week. Meantime, can you get me a decent top-down picture of the hub board - I need it good enough to follow the board tracks, and component names if they are screen-printed on the board (IE C1 C2 R1 R2 D1 etc). This will help me tell you which ones we can remove.