Toolmonger reader Russell Jones posted this great metalworking project on his blog. When the cheap-o plastic case of his USB key broke, he didn’t buy a new drive — he milled himself a new case out of aluminum. He ended up with a great industrial looking tech gadget that any Toolmonger would be proud of.
Russell started out with 1/4″x1.1″ aluminum stock that he milled on a Bridgeport milling machine. He made cavities for the flash memory innards and the LED activity light, and he cut a hole so he can attach it to his keyring. Then he drilled and tapped six screw holes to hold everything together. Finally, he polished everything up to a brilliant shine.
With some simple tools and a lot of ingenuity, he created a great looking finished project. Check out Russell’s blog for a better idea of how he did it.
USB Drive Armor [rj3labs.com]