Obsevarion with Terapod:
1. The Samsung 1T runs as cool as the BP4 256g. The BP4 has been on two international week long trips and has performed marvelously. I am currently running it on a 1300 mAH Li-poly battery and can get at least 4 hrs continuous playing time. (I haven't truly stressed it yet, i am sure it will go longer). Battery is pictured below.
2. The same battery used in the Terapod works fine, but drains to a shut-down state during song loading. The shut-down is probably due to the battery protection circuit trying to save the battery when the amp draw is too high. This probably explains why the battery appears to completely discharge when loading 2g or more of files at a time. If the loads are broken into smaller batches, the battery does not fully discharge, the circuit does not shut the system off, and loads above 2g can be made.
The last observation strongly suggests a higher mAH battery will increase the Terapod's overall stability. I am heading to RadioShack tonight to get a Li-poly battery to test with a PCB board recovered from an old battery.
BTW, the thin LI-poly batteries, up to 900mAH failed in my tests. Cmarti, were your batteries Li-poly or straight up Li-ion? This might also be a clue to you success.
Terapod now has about 20g on it. I will keep going until it is full (or until I run out of files). Still hoping my batteries arrive today.