You don't need many tools to do this, so have fun!
EDIT: And there's now another wooden USB drive Instructable out there so check that one out too!
Step 1: What You Need
You'll also need:
- a saw (the smaller and finer, the better)
- a chisel (if it's not sharp, check out my Instructable on sharpening!)
- drill (optional) - for the keyring hole
Step 2: Shim It Up
As I mentioned in one of my comments in the previous step's picture, the USB drive as it is, in its bare state, is too thin to make contact with the USB port. So you have to glue a shim onto the bottom of the drive in order for it to make contact with the port.
So clamp up a piece of wood and then use your saw to slice off a thin piece for your shim. I use Japanese saws myself, love 'em!, but use whatever works for you. I cut my piece way too thick as you can see in the second picture, so I sanded away, testing in the USB port from time to time until the USB drive + shim fit well.
Step 3: Cutting the Stock
Take your chisel and score your lines for the recess (with hand pressure or a light mallet tap). Be sure you are leaving enough of the USB drive sticking out so that it will go all the way into the computer! Always err on the side of not going far enough out - you can always expand your slot outwards later if it's not big enough. When checking for depth, try to get the USB drive perfectly flush WITH the shim in place (picture 2).
Next, cut out the block to the desired width. Since this is a tiny USB drive component, I wanted to go as narrow as possible. Be sure to leave a little extra for sanding and rounding off the corners, if desired (picture 3). The advantage with using a thickish piece of wood for your stock is that you can cut the second piece of wood at the same time and you'll be sure it will be the same width as its mate (picture 4).
Step 4: Shaping and Gluing
After you've shaped your wood as desired, now's a good time to add your keyring hole. I did it pre-glueup but you could do it afterwards too. Then I glued my USB drive to the shim with super glue, and then the drive/shim component into the recess.. Looking back, I'd recommend wood glue for the second glueup, as the super glue discolored the wood slightly where the USB drive comes out. Then use wood glue to join the two pieces of wood together and clamp them together.
After the glue is dry, this is a good time to round off all those sharp edges if you want. Then I cut a thin strip of sandpaper and "flossed" the keyring hole so it had a more rounded-in look. Now you're ready for the finish!
Step 5: Finished!
Thanks for reading, and hope it works out for you!