After seeing all of the great Instructables that people have posted if unique flash drive casings I knew that (at that time) nobody had made one with the Pink Eraser. I was surprised that nobody had done it yet, so I got started. Little did I know as I was creating mine, "fungus amungus" had beat me to it. Because it still worked, and I've been trying to find some excuse to post my own Instructable, I'll show you how I did it.
1 Flash drive
2 Pink Erasers (casing, and lid)
Steak Knife, or Scissors (to cut the erasers)
Xacto Knife (to pry the casing of the flash drive)
Drill w/ medium sized bit, or Rotary Dremmel (hollow out the erasers)
Silicone (to secure the drive into the eraser)
Tweezers (to grab excess debris from inside the eraser)
Shop Vac (The eraser debris gets EVERYWHERE!!!)
Step 1: Select Your Victim!!!
I chose to use a "Lexar 256MB" flash drive. The lens for the LED was broken of when it broke off my key ring, and the label on the back that said "256MB" was illegible. This flash drive was ready for a new suit, and Wallgreens had the most expensive pack of 2 pink erasers I could find at a whopping $1.32(after tax). I saw a pack at Target for $0.97 (before tax), but turned it down because I assumed Wallgreens was cheaper.
Anywho...Use an Xacto knife to pry open the casing of the flash drive. Mine popped open just as I got the knife through because it was just ready to be free. Make sure you don't go too far into the drive with the knife, you could cut off a piece of the circuit board if your not careful.
Step 2: Cut the Erasers
Your gonna wanna cut off the very tip of the first eraser (the wedge), in order to make it strait. Make sure you cut it strait down (like cheese), instead of back and fourth (like a steak).You'll have to cut about an inch off of the second one for the lid. You may be able to get away with 7/8in.
I chose to use a Steak Knife, but you can use scissors, or a band saw if your REALLY careful. In retrospect, I should have cut it strait down. I cut it back and fourth like a peice of meat. It came out worse that way. I didn't realize this until I tried cutting it strait down for the cap. It came out so much better. Take this as an example of what not to do. It comes out looking like a fillet of salmon if you cut back and fourth.
You can see the difference in the picture. There we're too many shreds of eraser to show exactly how much I cut off. sorry.
Step 3: Hollow Out the Erasers!!!
This has got to be the hardest part of the whole project. It make the biggest mess, and I shold have done it differently. I chose to use a drill with a 3/32 bit. I assumed that the drill bit would go through and pull out chunks of debris like it was meant to do with wood, but it didn't. It just went in and made hole that closed up after I removed the bit. It took me a good 40 minutes to hollow out the main case alone. I accidentally drilled through the eraser a few times, but luckily they closed up after I pulled the drill out.
Anywho, You want to go as far into the eraser as you can without drilling through it. You also want to make the slot about 1/8in tall, and about 9/16in wide. same goes for the lid.
I recommend using a rotary dremmel instead of a drill. I didn't have one so I used what I had in my closet.
Step 4: Insert the Drive
Before you insert the flash drive (for the last time), fill the hole with silicone to secure it in place. Make sure you use as much silicone as you possibly can fit into the hole. Otherwise, you'll get air pockets, this also insures that if it had any wiggle room beforehand, or you made the inside walls to thin, that it will fe firm, and secure.
You can now insert the drive into the eraser. Make sure it goes all the way in there, or else the lid might not fit. There's no reason to put silicone into the lid, because that would be dumb, and not funny at all.
I chose to put silicone on the edge of the eraser where the usb tip sticks out, just to make sure it didn't chip away over time.
And your done!!!
This was my first try, so please remember that yours will probably look better. Cheers!