Brian, I can help you out. I just made myself a 2400Mah Hump pack tonight. It was actually easier than I thought. I just had to make sure the Iron was clean, and keep the cells from getting too hot.

Also, With the first charge, charge it SLOW. I set mine to .1 amp. It will get a better peak, and lengthen the life of the battery. After that, future chargings for AA or 2/3A cells should be around 1.0 Amp. This keeps the heat down, and allows a better charge. When the batteries get too hot, they can false peak easier.