I've made them for my family for Christmas 2009 and the really liked them (at least they pretended to ;-))
Check out this video:
UPDATE: Since 2011 you can buy the offical LEGO® Minifigure USB Flash Drive here. But considering the price and the looks of it, I still think it's a good idea to make them yourself.
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Signing UpStep 1: What you need
material:
-
a very small usb flash drive (e.g. EagleTec USB Nano Flash Drive or Delock USB Nano Memory stick)
(e.g. from http://usb.brando.com/eagletec-usb-nano-flash-drive_p00892c041d15.html or ebay) - a female Lego figure wearing a skirt
- self-hardening synthetic clay (e.g. “Apoxie® Sculpt”)
- a 2 by 2 black lego plate
- a box cutter
- superglue
- a Dremel (Felt Polishing Wheel, different grinding stones, precision drills)
- a small slotted screwdriver (to apply the clay)
- sandpaper (800, 1000)
- a black permanent marker









































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A very good idea and a nice job
I do mine as soon is possible !