DIY

CIRCUITS

USB KEY MAKEOVERS

These case-modded pocket drives move your files with style. By Brian Nadel

Memory sticks lack character. Even the nicest-looking ones are more functional than fun. But re-skinning a USB flash drive takes only an hour, max, and unlike a PC case mod, you’ll carry your creation with you. They also make cute gifts (“Thanks for the memories!”).

So far, I’ve done a finger puppet, a ChapStick, and 2 wood blocks, but these mini-mods are limited only by your imagination. Small toys, wine corks, or even a rabbit’s foot are all fair game.

Photograph by Sam Murphy

The hardest part is removing the case without damaging the circuit board. Most USB keys can be pried apart, but some require cutting (Figure A, next page). Then you just need to find the right cover.

Finger Puppet

A child’s finger puppet is one of the easiest flash drive mods. If the circuit board fits, you just need

MATERIALS

USB flash drive 1GB drives are as cheap as $5 now. Shop around and you can find them free or very close to it after a rebate.

Plastic wrap

Silicone glue or epoxy

Something to make a new enclosure This can be anything you want. I used a plastic finger puppet, a ChapStick container, and small blocks of wood.

Wood finish if you make the wood block enclosure. I used linseed oil.

TOOLS

X-Acto knife

Needlenose pliers for the ChapStick enclosure Woodworking tools for the wood block enclosure.

I used a saw, vise, drill press, clamp, belt sander, sandpaper, and lathe.

Make: 163