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Real Thumb Drives

Real Thumb Drives

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Published by rushabh21
Easy way to JAZZ up ur FLASH/ PEN Drives
Easy way to JAZZ up ur FLASH/ PEN Drives

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Published by: rushabh21 on Dec 04, 2008
Copyright:Attribution Non-commercial

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06/17/2009

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http://www.instructables.com/id/Real-Thumb-Drives!/ 
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Real Thumb Drives!
by
LasVegas
on February 19, 2007
Table of Contents
intro:  Real Thumb Drives!......................................................................................................2 Video....................................................................................................................2 step 1:  Supplies..............................................................................................................3 step 2:  Make the Mold.........................................................................................................4 step 3:  Casting is Set..........................................................................................................5 step 4:  Mark the Epoxy Cup.....................................................................................................6 step 5:  Prepare the USB Drives..................................................................................................6 step 6:  Mix the Colors.........................................................................................................7 step 7:  Add the Hardener.......................................................................................................8 step 8:  Pour the Mold!.........................................................................................................9 step 9:  Wait! Then insert your USB Drive............................................................................................10 step 10:  Wait again. Then remove from the mold......................................................................................12 Related Instructables...........................................................................................................14 Advertisements...............................................................................................................14 Customized Instructable T-shirts................................................................................................14 Comments...................................................................................................................14
 
http://www.instructables.com/id/Real-Thumb-Drives!/ 
intro:
Real Thumb Drives!
With this Instructable, I intend to show you how to make your USB Thumb Drive into any shape you wish!I've been collecting USB drives since they started getting cheap. Every one of them still works, but unfortunately, the cases that hold them never hold up. I carry one onmy keychain for a couple of months and the frame breaks off. I've seen Some others put their thumb drives into Altoids tins, but what benifit has that other than the initialWow! factor...I decided that I was going to cast my thumb drive into my own thumb! Unfortunately, I'd never done any type of plastics casting. Perhaps this was fortunate because Ididn't know it couldn't be done! I just thought about it for a couple of weeks. Finally I decided I was going to try it. Worst that would happen is I might destroy a couple ofold, obsolete thumb drives...After a little time at the local Hobby store and discussions with the cute little salesgirl, I decided on the supplies I needed. A little experimenting and I got the techniquedown.
Video
Image Notes
1. A little Dremel work cleaned them up nicely.
Image Notes
1. Second cast. A lot of apparent "cancer." The epoxy damages the casingmaterial quite badly, but it should clean up nicely with a file and snips. That canwait until the epoxy fully sets in a day or two.2. My first casting. Didn't mix the Epoxy as well but it firmed up fine.
 
http://www.instructables.com/id/Real-Thumb-Drives!/ 
Image Notes
1. This is the second casting. As you can see, there are a lot of defects. Theseshould clean up well enough.
Image Notes
1. This is my original test cast done the previous day. This was just to determine ifthe epoxy would even work in this casting material. As you can see the epoxy isrelatively color free so very open to coloring. The line from the tip to the right wasa nail I dropped into the liquid epoxy. (The same nail as the color test on the left.)2. I've included this picture to demonstrate that I did do some testing first. It neverhurts to make many practice runs before the real thing...3. This was my second test. Here I only used a teaspoon of epoxy and hardener. Iwanted to see how well the water based color would work with the resin. It tookmuch longer to harden fully, and it proved that I needed more yellow.
step 1:
Supplies
First I needed casting material. I could have used plaster or latex. Plaster would produce a very porous and hard mold and would likely only give me one casting. Liquidlatex would give me a nice, permanent mold but would take way too much time and work by building the casting in layers. Besides, the latex would very much irritate mythumb.What I finally decided on was a product called "instaMOLD" made by Activa Products, Inc. ($10.50US), a water based compound that would firm up in minutes and wouldbe reusable a few times. The problem is, would it work with plastics? What kind of plastic should I use?Searching the plastic compounds at the hobby store proved fruitless. All of them would harden too hard for what I wanted or were way too expensive. Finally it occurredto me that most of them were some form of epoxy. Why not use regular epoxy? Studying the different epoxies that were available I concluded that the longer settingepoxy would produce the more flexible result, so 12 or 30 minute epoxy would probably be my best choices. Besides, I'd want to color the epoxy before pouring it in themold and less that 12 minutes would probably be pushing it. This time, I'm working with the 12 Minute Epoxy ($9.95US).Lastly, I needed color... Flesh is actually kind of easy to mix. Just Pink and Yellow. Having no idea how well they would work I bought 2 bottles of Delta brand Candle &Soap Colors for $13.99US each. Note that because the colors are water-based, they will have an adverse reaction to the epoxy mixture. The epoxy won't firm up quite ashard as it would have, so we must use as little color as will produce the desired result. For my first color experiment, I used 6 drops of pink, 12 drops of yellow and ateaspoon each resin and hardener. The result was still too pink (need more yellow) and was a little too soft (actually eerily close to real skin & muscle!). I've decided that Iwill be using 6 drops of pink and 18 drops of yellow for the full casting (about 3 tablespoons of epoxy mix). We'll see how well it works by the end of this instructable! :)Oh yea! We still need the USB drives don't we? Well, I've currently got two without cases and a few more that can easily become case-less. That should be enough tostart with...Finally, we need a few small dixie cups, stirring sticks and measuring spoons. The dixie cups I used were the perfect size to cast my thumb and mix the epoxy.Disposable containers always make a project like this easier. Less cleanup!

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