Step 1: Gather Materials
-carving tools + saw
This can be tricky. You're going to need a block of wax to carve (actually some woods will work too, as long as they burn away cleanly and don't leave too much ash residue.) Wax by Kerr or Ferris is designed for carving and clean burnouts, it's what i'm using here. There are different hardnesses, in this project I'll be using green wax, which is both hard and brittle, but takes detail well and allows for very thin walls.
You will need a USB drive. You probably won't ruin it during this project, but you could, and it will probably void your warranty. Feel free to try it with an old 32mb drive or something first if you're unsure. I'm going ahead with my 1G drive because what can I say, I'm fearless.
You will need a place to have this cast. You can take it to a casting house (easy, fast, and pretty inexpensive) or you can cast it yourself. I won't cover that here.
You will need carving tools. You can make do with some scrapers, pointy utility knives, or dental tools, but the real king of speed and flexibility here is a rotary tool like a dremel or a foredom. You'll want some ball burrs, but try not to get anything too fine-toothed because it will gum up with wax pretty fast. A jeweller's saw frame with a spiral wax blade is reccomended, but if you've got a bandsaw or something that can do it, by all means use that.
That should be it.