In this instructable I will show the steps needed to remove the existing USB Flash Memory PCB from a Victorinox Securelock "Swiss Army Knife" Memory Stick and replace it with a larger capacity USB memory stick PCB (Here I use a Lexar 2GB Firefly that runs about $25)
I never carried a pocket knife in my entire life until I got the "geek's version" as a Christmas present 3 years ago from a friend. It is a 512MB Victorinox Securelock USB Memory Stick Pocketknife. Since I received it, it is in my pocket everyday and has become indispensable. As time has passed, I have outgrown the 512MB and now I also carry a 2GB stick. To lighten my pocket load I have been thinking about upgrading the Samsung Flash chip on the PCB, but alas the OTi2168 controller chip can only support chips up to 4 gigbits (512MB). I tabled the idea for a while until I was recently given a Lexar 2GB Firefly. Curiosity got the best of me and I popped open the case. The rest, as they say, is an instructable. (or something like that)
Step 1: Tools needed
Tools you will need
Step 2: Remove the PCB from the Swiss Army Knife module
Pop the memory stick out of the knife. The PCB (printed circuit board) is held into the case with two tabs that seat into holes on the USB connector. Using two Xacto knives, pry open the center of the case where the small tab is set into the USB connector. Carefully slide out the PCB by holding the top and bottom of the connector.
Step 3: Open the Firefly
The Lexar Firefly case is a snap together plastic case. Using an Xacto knife, pry open the case near the connector until it pops open. Carefully work your way around the rest of the case to pop it open. Remove the LED lens that is clipped to the end of the PCB.