Metal USB - Flash Drive Case Mod




A case mod for a Flash Drive made with a heatsink.

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Step 1: Find Parts

You will need:

Flash Drive I used a PNY attache (256 - yeah, it that old (2yrs))
A metal case I used a heatsink form a dimmer, but anything should work (golo e115041 sc237)
Keychain Flashdrive -keys= external hard drive I'd reccomend something, but it's not critical
Nails I used a strip of brads for an air nailer, but anything will work
Glue Super glue (loctite gel) and plastic cement (testors -for models)

Drill For attaching keychain and a hole for the light (I was lucky and didn't need a hole for the light)
File Sharp corners, etc
Hacksaw blade you can use a file instead
Leaterman Do I even need a reason?! /Just cuz
A Brain Don't cut yourself, ruin your computer, etc IF YOU DO IT"S NOT MY FAULT

Step 2: Case

If you need to file, cut, etc the case to the right size. File the edges and drill the holes for the keycain and light. Using some sort of spacer cut a slot in the inside of the case for the board of the drive to slide into.
It's hard to give general instructions for this sort of thing so bear with me and look at the pictures.

Step 3: Put in Drive

Depending on your drive you might want to wrap it in tape to prevent it shorting on the metal case (you can also use plastidrip spray). Slide the drive in the slots you cut earlier use lots of glue to hold it in place or it will break like it did the first time I did this. If it needs it glue a space on to of the drive. Break the strip of brads to the right width (I score the glue on both sides with the knofe and snap it) and glue it on top. Use a generous amount so it doesn't break. Remember that if you are anything like me you will carry this in your pocket evey day for a couple of years, so it needs every drop of glue it can get. Let it dry over night before carrying it.

Step 4: Final Thoughts

My flash drive lasted me 2 years before it broke and hopefully it will live many more years. As the case gets old it starts it get scratched (aluminum) and develops some character giving it a very industrial look.

I hope you enjoyed this instructable as much as I enjoyed making it.

Please leave me a comment with suggestions, improvements and other ideas.


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    43 Discussions


    Reply 9 years ago on Introduction

    You can get ring clips like this from quarter toy machines, or crafts stores like Micheal's is the US.


    10 years ago on Step 4

    dimmer switch...I think he is talking about one of those "slider switches" for your house. They dim the lights when you slid it up and down...but I'm probably wrong.


    10 years ago on Step 4

    That is a pretty sweet idea! Where was this heatsink form? that's the only part i was confused from.

    1 reply

    it might be more shock-proof if you seal it in silicone. Also, could you drill a hole in the heat sink for the little flashy LED on the drive? I like this a lot! If I pull out the money to get myself another flash drive to hack up, I'll definitley do this!

    1 reply

    11 years ago on Introduction

    I like this one a lot. It has a kind of 60's-ish spy movie look. I can almost hear the theme from Mission Impossible. :-)

    1 reply

    Reply 11 years ago on Introduction

    Thanks! I'm doing to rebuild this soon because the plug broke. Hopefully I'll put some pics up soon