Step 1: Supplies!
When I saw this little dude, I knew it would fit nicely in something. The working parts are contained entirely in the plug.
So, you will need:
OCZ Roadster (appropriate, eh?) flash drive. I think these go up to 4 gig; this one's 1 gig.
Update: I was recently thinking of making another one, and found that this flash drive is no longer made! I couldn't find anything like it. Bummer!
Matchbox/ Hot Wheels car. I just took the drive to the store and held it up to various cars until I found one that fit. Turns out, the Mini's perfect.
Drill with a 3/16 bit
Jeweler's saw, a cutoff wheel in a Dremel might work
A fine file, a set of needle files is a great investment for this sort of stuff
Hot Glue Gun, What else would hold this together?
Step 2: Dismantle the Car
These things are held together by stubs from the body rivetted over on the underside holding the bottom of the car on. It is a simple matter to carefully drill off the peened metal, allowing the "chassis" to separate from the body. (Don't drill through your hand.)
Step 3: Deconstruct the Drive
Step 4: A Little Rear Axle Work
With the X-acto knife, cut off the heads off the rubber plugs. Poke or drill a hole through the center of each plug. This is a little trickier than it sounds due to the d-shaped part on the inside. I sliced a little channel in that part so the axle would be right in the center.
Assemble the drive and wheels. I was thinking I'd have to glue one wheel on because I filed the head off, but I got lucky and there was just enough burr left to hold the wheel on. A few months later and it still hasn't fallen off.
I also cut the lanyard loop off the flash drive case, and had to file a little off the bottom edges to get the wheels to be on the "ground".
Step 5: Chassis Mods
Step 6: Interior Mods
Step 7: Body Mods
Step 8: Test Fit and Glue Up!
Step 9: The Showroom Floor and Test Drives
The maroon retractable one is my favorite. The only problem with it is that because of the orientation of the slider, when it's plugged into a port on a computer, the car is upside down. But when you use a cable, the drive lights up underneath the car! Pimp my flash drive!
The skull car was cut in half with the jeweler's saw, and a USB plug cap was glued into the front half. It's surprisingly secure, and rolls just fine.