Based on some ideas in the eevblog forums, I replaced the TDK inductor I used in the first videos with a Sumida RCH-855np. The sumida specifically says…
• Ideally used in Printers, LCD TV, DVD, Copy Machine, Mainboard of the compounding machines etc. as DC-DC Converter inductors.
Since the TDK data sheet was a bit ambiguous and stated it was for “Power lines” there was a theory that the TDK may have actually been a choke. Turns out the results show pretty much the same performance. I was unable to get above 67% efficiency. I would really like to see someone do better with this chip on video.
I think my next step will be to but the Adafruit kit for the minty boost, which uses the LT1302 chip in its design. I am curious to see the results on a professionally designed pcb with a similar chip.