OK, I was looking at evilmadscientist (the recent 20 millicentury article with the "use bike tubes as rubber bands" link and picture in it) and Tommi Potx's bike tube instructable, as well as cursing my busted flash drive casing, when I realized I could use an old bike tube as a new case.
EDIT: I just found that it was quite similar to thearchitect's flash drive "case mod" (right here), except in rubber, not leather. Giving credit where due.
You'll need:
A flash drive you can remove the case from
A bicycle inner tube
Rubber cement
Good scissors or x-acto knife.
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Step 2: Slice time, part 1

Get out your old (bicycle) inner tube and hack off your desired length of tube. For my PNY orange 2G drive, I used an 8 or 9 inch section.

Step 3: Slice time, part 2

Now, take your section of tube and slice it down the middle to make a flat piece of rubber. I would suggest washing the talc out of the tube at this point. It will hinder later steps.

Step 4: Slice Time, part 3

Now, take your new section of rubber, and slice your desired width strip of it (mine averaged out at about 1 cm). Take the extra rubber and add it to your patch kit.

Step 6: Glue.

Now do you see why you wanted to remove the talc? Glue and talc don't work well together. Take your loose end of rubber and some rubber cement and glue it down. Simple as that.
andreq6 years ago
You could use Plastidipand have a nicer finish ;)

wow, i should try that some time...
orangesrhyme (author)  andreq6 years ago
Sweet, dude, I'll check that out when I get my new flash drive.
carpespasm6 years ago
I'd say filling the original case with some epoxy and tool dipping it once you put it back together would yeild a much more rugged case. As it is the PCB is taking any strain exerted on the plug while if it were made solid with epoxy not only would it be pretty much waterproof but it would also even strain and add further impact resistance. Wrapping it with rubber tubing or tool dipping it would be a good further step, but at least you're thinking about these things. Keep it up.
I just covered mine in Epoxy. Waterproof, and about as crush-resistant as this. Lot easier, too.
cotton6 years ago
be carful when opening thes my was melted shut by the factory and i stabbet my self three times witha screw driver
orangesrhyme (author) 6 years ago
all right, I'll get to work in some better lighting... After I fix my flash drive. You see, when my drive's case broke, it considerably loosened the USB "prongs" and I was being careless with my ruggedized one and broke one off. I might end up just replacing it. New photos when I decide.
bytowneboy6 years ago
I can't see what you're doing in most of those pictures.
You need better images, please, but the idea is good.