In a complete and utter diversion from the world of woodworking, I was surfing around online, and happened upon yet another USB key design. Thinking I could do a similar job, I hunted around for a spare USB key, and grabbed a few 2×3 lego bricks, some 2×3 plates, and 1 each of a 1×3 brick and plate. That’s all that was needed. I hollowed out the insides to fit the key, and epoxied and super glued the bricks together. I then sanded down the sides with a bit of wet or dry sandpaper and some Brasso. Neat. Isn’t as pretty as the original article’s, but for a first try, not too bad.
Update: I’ve posted some more USB key images. Some of the smaller ones use a Firefly USB drive from Lexar. They are the smallest memory key I could find to fit into a 2×4 brick. They just manage to fit.