OK, here we go!
What is needed:
- Burned-out light bulb (mine was from Philips, 12V 21W E1)
- USB Memory drive of course (Recon Data 2GB, Hynix module inside)
- Electric pliers
- Electric wire cutters
- Some screwdriver
- Engraving pen for metal
- Soldering iron and tin wire
- Insulating tape
- Little file
Let's start! ->
Step 1: USB Memory Drive Disassembling
In order to take off the two plastic caps, we can use first a cutter and finally the knife, pics 3 & 4.
Now we can remove memory drive from aluminium shell, pic 5.
This time, pull away the two pins from the back plastic cap, pic 6 & 7.
In the last pic the naked memory drive!
Step 2: Working on the Light Bulb: Measurement!
First of all use caliper to determinate width of memory drive PCB (Printed Circuit Board). Then compare measure just obtained, on light bulb diameter in order to find right point where bulb will be saw... In this case, I got 14 mm width for PCB. Take notice that thickness of glass bulb is around 0.75 mm, so it means that I should have determinate a diameter on the bulb bigger than 15.5 mm in order to be sure that memory drive will go into the bulb. Well, note down measurement...
Step 3: Working on the Light Bulb: Remove and Clean the Cap Sleeve 1
Step 4: Working on the Light Bulb: Remove and Clean the Cap Sleeve 2
Step 5: Working on the Light Bulb: Remove and Clean the Cap Sleeve 3
Step 6: Get Memory Drive Housing: Mark and Cut USB Hole
The cap is made in metal that can be easily cut, so you can use wire cutter; simply follow the guidelines and bend the two "wings" inside the cap. As I said before, use a file if needed.
Step 7: Get Memory Drive Housing: Put Inside and Solder
Step 8: Saw the Glass Bulb and Glue It
Take the glass bulb and wrap insulating tape around the bulb where you have determined at step 2. The tape will help you to cut around the glass bulb with the engraving pen. Be patient and careful, you will have to cut around the bulb many and many times, slowly, in order to make glass more thin so you can separate the two parts. If you will be impatient, you will break glass!
When done, you can paste the empty glass bulb on the rest of housing, inserting memory drive PCB inside glass bulb. If memory drive have difficulty to enter inside the bulb, you can use a file to make thin the edges of PCB and bulb (where PCB and glass have contact). Again, be careful this time also or you will void the project! After that, you can paste parts together; I used universal glue from Pattex
Step 9: You Have Done!
Thanks for reading