This is the older one of my flash drives, and is badly in need of a new shell. Notice the cracked plastic near the neck (See the second image below).
Of course, the simplest solution would be to superglue it. But that would not have been as fun, right?
Step 1: Taking apart the flash drive
Because of the crack in the shell, the flash drive did not hold together anymore. So, taking it apart requires no effort at all. If you have a similar flash drive, in intact condition, all you need to do is gently press the tip of a tiny screwdriver onto the blue part.
Let's remove the blue collar as well. Be careful not to damage the electronic parts. The plastic parts will go to the trash, but I am saving the cap for my friend Shain. He has the same flash drive and has lost the cap!
Step 2: The new shell
Here's our naked flash drive with the two pieces of (knock off) LEGO that will serve as the new body.
Step 3: Carving out the bricks
Next we carefully carve out the circular bits in the middle with a small cutter. I love plastic because it's so easy to work with.
Step 4: The fitting
After we carve out the insides of both pieces, we need to try things out. There seems to be no problems with the bottom side.
The metal shell of the USB connector however, seems to be an issue for the top side.
Step 5: Getting into the groove
All we gotta do is carve a groove for the USB connector on both bricks. Here, the small file is my best friend. Plastic is soooo easy to work with.
I need to carve just a bit more to get a proper rectangular shape. Remember to do the same for the other brick piece as well.