Please vote for this instructable and feel free to ask any questions.
Step 1: Materials
a x-acto knife
a piece of paper
Foam core poster board
a glue stick
a hot glue gun
Paints (and any extra materials to colour or design your USB)
Step 2: Design
NOTE: your design must accommodate for the size of the USB you are using
Step 3: Transferring the Design
NOTE: do this step twice as your Shuriken will be two cut outs stuck together to accommodate the thickness of the USB
Step 4: Cutting Out
NOTE: take time to cut your lines to keep them straight. Make sure your lines are cut properly to avoid tearing the poster board.
Step 5: Bevel the Edges
Mark out a line on the cut out stars about 5mm (1/4 inch) from the edge. Score this line just cutting through the first layer of paper (this will make it easier to cut out the bevels). Take your x-acto knife and at a 45 degree angle cut around your design. You should now have a 45 degree bevel around the outside. (do this for both peices but invert the bevel so they come together to form a sharp point)
NOTE: take time to make these cuts as to not tear the foam or paper. And again be safe with knives.
Step 6: Make the Lid
Step 7: Make Room for the USB
NOTE: don't cut through outer layer of paper, this will ruin the outside
Step 8: Finishing
I decided to paint my Shuriken black with acrylic paint to seal the foam and then coated in Spray Paint and cut notches to give a broken and battered feel. I then covered the sides in aluminium foil and re-cut the noches to make them visible.
This can be your design so do what you want with it, make it creative!