So I broke my USB stick's case and had to think long and hard about what to re-case it in. After a search of my house, I found a couple of old shotgun shells, and this idea was born.
Help clean up your local hunting sites by collecting shotgun shells!

Step 1: Materials

Gather materials.
You will need:
- Two 12 gauge used shotgun shells (This means already fired, empty. NEVER EVER cut into a live shell) If you're wondering where to get used shells look in shooting ranges or hunting grounds but make sure they are aware of your presence and there isnt a hunt going on. One needs to have a longer brass casing (about 25mil in length)
- One USB Flash Drive
- A knife
- A cork (not pictured as I didn't know I needed it)

Step 2: Cut

No measuring here. Just cut the longer shell down to the brass. It has to be at least 25mil long otherwise it won't fit.

Step 3: Clear It Out

Clear out the case down to the white plastic at the bottom. You cannot fully remove this because it is attached to the head by the primer. I just left it in.

Step 4: Cut Again

This part will be the case for your drive so make sure to measure it. Take the drive out of its case and place it inside the shell. All USB devises have indents marking in how deep they fit into the port, so only up to them will need to be showing out of the top. Mark around this line on the outside and cut.
Always remember you can cut more off but not put more back on, so cut it a bit too long first.

To test if it's the right length, temporary attach the drive into the case (I used bluetack, fairly foolish and hard to clean up), and place the lid on. it should fit on snugly. Mine fitted on about 7mils.

Step 5: Cork

I originally planned to place the drive in there in its case, as it was a snug fit. Unfortunately, but ironically for the better, I measured it on the outside and cut the case too short so it didn't fit.
Being British, I used my initiative and took inspiration from =SMART='s Champagne USB key and fungus amungus' Pink Eraser USB Flash Drive. (unfortunately I forgot to document this solution). I got a cork and cut it down so it fitted tightly into the shell with no gaps. I then marked out the flash drive on the top and used a dremmel to drill / bore a hole into the cork.(see other two instructables for details)

Step 6: Finish

I wrapped my drive in electrical tape (for better or for worse?) and then slotted it in the hole. You can use the slithers of cork from the previous step to wedge it in. Clean up your edges and you're done. Have fun with your new case.