DIY: Teak USB Drive

I have had this 1G usb drive around for a while and the enclosure had broken, So I made my own wooden enclosure!

Materials

• wood (teak)
• USB drive
• foam padding
• two part epoxy
• wood glue
• sand paper

Tools

• table saw
• belt sander
• drill/ drill press
• clamps
• razor blade

Step 1: Size Your Wood

After you have gathered the required materials measure out the wood to the right size.

1. measure your usb drive
2. mark on your wood how you want it to sit

Step 2: Making the Cut

This part is a little dangerous, use proper safety gear.

1. hollow out the main body to 1/8"
2. do the same for the lid peice
3. cut the main body in half
4. do the same for the lid peice
5. cut two 1/8" strips to form the top and bottom caps

*USE A PUSH STICK, GLOVES AND SAFETY GLASSES*

Step 3: Glue It Up

Get your wood glue, epoxy, clamps and foam

1. glue the two main body peices together and clamp
2. cut your foam to shape (foam goes in the cap to help secure it)
3. epoxy foam to both halves of the lid (allow time to dry)
4. trim the foam down with a razor to get a snug fit
5. with wood glue, glue the two parts of the lid together and clamp
6. take the 1/8" parts you cut for the caps and glue those on next

Step 4: Trimming and Finishing

After the glue has set

1. trim the bottom and lid to size
2. if your usb drive has a light measure where that would sit in the body and drill a 1/8" hole in its place
3. mix your epoxy and fill the bottom with the epoxy and quickly insert the usb drive
4. hold the usb drive in place so it is straight  until the epoxt has set
5. after the epoxy has cured even the body and lid out on a belt sander
6. round the edges and hand sand the enclosure
7. apply your choice of finish
8. your done now load it up with music and files

Thanks for looking and as always, please rate/vote as you see fit.