Step 2: The Practice Run
As I mentioned, I started with the Backspace key for a test-run. My plan of attack was as follows:
1. Dremel a notch into the side of the key.
2. Sand edges smooth.
3. Place the USB drive into the key.
4. Pour clear silicone into the key to secure USB drive into place and to allow the back side to be see-thru. However, for the practice run, I actually skipped steps 1 thru 3 because I was mainly concerned with how well the silicone would work as a filler material.
I was really glad I did a practice run. The day after I finished applying it, I was not happy with the clarity of the silicone; it was too cloudy. It was also a bit softer than I wanted.
So, I decided to use something else for the real thing: an industrial strength adhesive called E6000, which Brian has used in the past and recommended. That being said, about a week later I checked the silicone again and found it to be much harder. Apparently, it just needed more time to set. Still, the clarity wasn't quite as good as I wanted so I still planned to use E6000 in place of the silicone for the real run.