Introduction: LEGO USB Case

I had a USB memory stick that was coming out of the case so I made a new cover for it using a Dremel & some 2x2 LEGO pieces.

Step 1: Things You Need:

  • USB flash drive
  • Dremel
  • Drill & Routing bits for your Dremel
  • 2x2 LEGO bricks--enough to cover your memory stick completely
  • 2 2x2 LEGO plates
  • Tacky Glue
  • Safety Glasses & face mask
  • Sugru (optional)

Step 2: Preparing Your Memory Stick

The first thing you want to do is remove the cover on your memory stick. In some cases this will be easy because, like mine, it was already coming apart. The USB memory sticks we used for our Dremel Build Night project proved a bit trickier. Be careful removing the cover as you do not want to damage your memory stick. We tested them after removing the covers to be sure they still worked!

Once you have removed the cover from your USB stick, create a stack of LEGOs next to it to help you determine the number of LEGO bricks you will need. My memory stick was quite long so I needed 8 bricks, the other sticks we used for our project only needed 6 bricks.

Step 3: Preparing Your LEGO Bricks

Now that you know how many LEGO bricks you need, it's time to get them ready to hold your USB memory stick.

First, stack them up and, using your Dremel with the drill bit attached, drill a hole down the center of all the brick pieces you will need to cover the bottom portion of the memory stick.

Next, using the router bit on your Dremel, remove the round piece on the underneath part of the LEGO brick and create an opening that your memory stick can fit in snugly. Do this for each brick that will fit over the bottom portion of the memory stick. NOTE--this is a dusty job so be sure to wear safety glasses and a face mask if you don't want to breath in any dust!

Step 4: Preparing the Cover Piece

Once you have the bricks prepared to cover the bottom portion of the memory stick, you are ready to prepare your remaining bricks for the cover.

Because the top portion of your memory stick is larger, you need a bigger opening in the bricks to fit over it. The best way to do this is to cut a plus sign shape in those pieces. This part is a bit tricky so you will want to cut a bit out and fit it over to be sure that it's going to fit properly and stay on. If you still can't get it to stay, try a little SUGRU in the lid portion to help it stick when you want to put the lid on.

Step 5: Putting It All Together

Now that you have all of your bricks ready, you are ready to cover your memory stick with your bricks.

I put the bottom together first, placing one brick at a time over the memory stick, using a little tacky glue on each piece to hold them together. Wipe any glue that squishes out with a piece of cloth.

On the top of your lid and body pieces attach a 2x2 plate piece to give it a nice finish.