Creating a case out of Lego to house a USB memory stick. This has been done before but I haven't seen it done like this :)
Step 1: Creating the Case
Because my memory stick was quite large (in dimensions, not in storage capacity) I had to create a 6x3 Lego brick. I chopped a 4x2 and a 2x2 brick in half using a pen knife and another brick as a guide, the pliers on the same penknife were then used to remove the inner bits of the bricks and then the knife was used once again to remove the sides. Another 4x2 and a 2x2 brick were then used to create the case.
The four parts were stuck together using super glue and a steady hand.
Step 2: Installing the Stick
A groove was cut into the case to locate the USB connector and after a small amount of modification to the PCB the stick was installed.
Step 3: Securing the Stick
I stuck an offcut of one of the bricks at the bottom of the case as I found this made the stick sit at the right height. I then packed the whole thing full of clear silicone to made it stronger and reduce any movement from the stick.
Clear silicone was important as it still allows light to shine through.
Step 4: Stick It Together and Polish
I stuck a flat 6x2 and 6x1 brick to the top of the case to enclosed it all. Because of the amount of joins and glue lines some of the bricks weren't totally level so I used some fine wet and dry paper to level the edges up. Two different grades of metal polish were then used to make the edges smooth and shiny again.
Step 5: Finished
The finished product, the second image shows the original case for the memory stick and the final image shows the LED in action.
I was tempted to make an end cap, but it'd annoy me and I'd only loose it.
Have fun :)