Project: Enter the USB was created by Kurtis Kronk for TheTechLounge.com. You can see the original article published online here.
After the practice run, my plan of attack remained mostly the same, except for the first and last steps:
1. Remove clutter from inside the Enter key.
2. Dremel a notch into the side of the key.
3. Sand edges smooth.
4. Place the USB drive into the key.
5. Pour E6000 industrial strength adhesive into the key to secure USB drive into place and allow the back side to be see-thru.
Before pulling out the Dremel, I donned my protective gear. Kids, don't try this at home. I'm a trained, erm... heh... professional. Yeah.Step 1:
The first thing I needed to do was get the little stub in the middle of the enter key out of my way, as well as the little pieces of plastic jutting out that supported that bar I removed earlier. For the stub, I bashed the key with a large stone. No... why would I do that? Safety in mind, I proceeded with my Dremel and fingerless gloves. The cutting wheel was used to cut in some notches first and then the grinding stone was used to actually remove pieces. Using only the grinding stone on plastic tends to melt it all into one big sticky mess. By cutting notches first, I was able to use the grinding stone pretty much exclusively to remove the little plastic pieces that supported the bar.Step 2:
Before cutting a notch into the side of the Enter key, I grabbed a pencil and the USB drive to mark approximately how far I needed to cut. Once again I used the notch-then-grind method with the cutting wheel and grinding stone for the side of the Enter key.Step 3:
I was able to clean it up pretty well with the Dremel, and then put on the finishing touches with some fine grit sandpaper. Care had to be taken with the sandpaper to not round any corners or edges, though.Step 4:
With all the necessary cuts having been made, it was time to place the USB drive inside the Enter key. Fit was perfect, with a little bit of wiggle room.Step 5:
Now for the fun: pouring in the E6000. The tricky thing was that this part had to be done a bit at a time, rather than all at once, to keep the E6000 from flowing out of the notch we just cut. So I started by filling the key up to the notch and then setting the USB drive back in place on top of it. I let it set for 24 hours, then added a bit more, and so on, until silicone was up to the top. Once I was completely finished, I let it set for another few days before messing with it, since I used a good bit more E6000 than your typical application.