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.
Step 2: Press home....do not glue
I didn't glue the plug into place, as this would have meant that the eye mechanism would not have worked any more. The lever on the back of the head still makes the eyes scan.
Step 3: Actions stations!
The Action Man usb is complete.
It is by no means elegantly finished.....May need some refinement (as there is a danger of dust getting in just now)...but in essence it is done....and I just checked, the process hasn't affected the stored files at all.