Step 1: Step 1 - Materials
1 - Pen/marker
1 - Pair of Scissors
1 - Ruler or straightedge
1 - Bottle of krazy/nail glue (You could use tape or regular glue as well)
Approx 20 - Playing cards
(Not In The First Picture) I found later in the process of making the case that a razor blade or exacto knife can be very helpful.
Step 2: Step 2 - Thickness and Card Quatity
The stack i used was 24 cards thick. i started with a large stack of cards and pushed my flash drive through to get the thickness of it in card lengths. Mine was 14 cards thick. I then added 5 additional cards on either side for structural support that WON"T be cut for a usb opening.
Step 3: Step 3 - Setting Up the Front and Back
Repeat that process for the back 5 cards.
Step 4: Step 4 - Cutting the Cards
After cutting the middle cards (No more than 2 cards at a time) You must get out your adhesive and fasten them together, a drop in each corner should do nicely.
Step 5: Step 5 - Cutting the Middle
Just for a moment, put the front and back cards off to the side.
place the USB on top of the bottom stack of cards so that it can still be placed into a USB drive and proceed to trace around it with your sharpie. Try to get as close to the size of the flash drive as you can. later on you will find the more snug it fits the better it will turn out.
Repeat this step for the top half of cards, this will be the cap.
After marking, you may start to cut with scissors and finish it up with an exacto knife.
It may look particularly rough around the edges where the flash drive is set but don't mind those, they will go away in the next step.
Step 6: Step 6 - Adding the Last Pieces
Just as every other time, a drop in each corner should be plenty.