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I carried out some further testing today (current titanium D1, but previous aluminium model very similar). 700c wheel size, speed by GPS.
No load
22kph - no heat
25kph - minor heat, few degrees extra
30kph - heating obvious at bottom of casing (where protection lives)Charging Sony phone @ 470mA
22kph - no heat
25kph - no heat
30kph - minor difference I think, barely noticeable.As long as the D1 lives outside the heat isn't significant, on the titanium one mounted on the head stock it cooled to ambient in 20 seconds (or so) after the speed came back down from 30kph at 60 seconds. I would not recommend putting the aluminium one inside a bag, it will insulate it.
acharnley
My average moving speed is between 25 and 29km/h on long distances (depends on how many mistakes I make, and if I'm going solo/group). The main group normally do around 19-22km/h trying to avoid the brevet time limit.
Two different models could be seen as a logistic problem for you, but it could be great to have a specific unit for touring/mountain biking (slower as you said) and another for "roadies" that average higher speeds, not just on descents. It would be another great reason to choose D1 above other market options... something specific is always better, unless you want to use it on different bikes for different rides
I suppose that integrating a button or a switch in the case would make it bigger, and also maybe not convenient for some unit placements, I'll think about a solution but this something like this could be great, to place it on the handlebar or frame.
I've used one of those USB extension cables too, because the power-bank doesn't have a cable, you must connect it to a female usb port, and it was a great solution.