Inspired by the lego usb, I searched around for a suitable toy to use as the basis of a customised usb stick of my own and remembered that I had the head of an Action Man, tragically removed years ago.
It seemed eminently suitable.
Step 1: deconstruct Actionman head
This particular head came with moving"Eagle" eyes which I hoped to retain. I removed the head-connecting plug, which revealed the mechanism for the eyes....basically a drum with connections around its side....so that the inside of the drum will retain a usb chip board quite easily...snugly in my case.
I sliced the top of the head plug off, widened it with a file to accommodate the usb end, pushed the usb through it and then inserted the plug back in the neck aperture.