Rock Solid Cement Flash Drive

Submitted by Matt on Wed, 08/09/2006 - 6:00am.

Instructional

Fig. 10

Why a cement USB drive? Well that answer simply is this, because I can and want to. I was unsatisfied with my newly purchased 1GB flash drive. The drive worked fine but the design was horrible. The case protruded so much that if you tried to plug in another USB device you would have to bend the port just to fit it in. I don’t know about you but I’m not going to break a port on my $1000 laptop for a $13 flash drive. So the following is a step by step guide to making a rock solid flash drive.

Technorati Tags: DIY, electronic, flash, howto, Make, thumbdrive, usb

Please read all the directions and precautions before attempting.

• Cement is bad for your skin and eyes. If any comes in contact with your eyes wash out immediately with fresh water and seek medical attention.

• Razors are sharp. Don’t cut yourself.

• This process could damage your drive. Back it up Before you attempt.

• I am not liable for any damage to your data or hardware. Attempt at your own risk.

Step 1: Find some cardstock, plastic, or business card. Trace around the male part of the USB. There bottom should be no more that 1/16th of inch between the bottom and edge of card (see below). This is crucial, if you do not take the time here your drive will take up more than one port.

Fig. 1-1

Step 2: Use a hobby knife or razor blade to cut a hole (see below). Test fit hole with USB (see below). There should be no extra space between card and USB.

Fig. 2-1

Fig. 3-1

Step 3: Test fit card in mold (see Fig. 4). This should also be a snug fit with no gaps. The mold I used was 1x1x11. You might have to get creative at this point and make your own mold. A metal or plastic mold is ideal because they will not absorb water. You might want to try balsa wood. When making your mold make sure that you leave ~1/4 inch on each side of your drive and ~ ½ inch at the end. This will ensure that the drive is completely covered.

Fig. 4-1

Cement: You have many choices in regards to cement. Some are much better than others. For this project I recommend you use rapidest cement or an self leveling (SL) cement. The rapidest will give you results faster but with a little extra work in the end. The SL should give you a nicer end result (I have not tried the SL yet so you fly solo on this one).

If you use the rapidest then follow this formula. 75g of rapidest, 75g of #70 silica (sand), and 75g of #30 silica. Mix these three components well. You will be adding the powder to 14g of water and mix well. You will have about 15 minutes of working time.

Step 4: Place your card into the mold. Next you lay bed of cement ~1/16th of an inch (see below). Now place you drive in card. If you are using the SL you may want to place the drive in the card before pouring any cement. The SL should be very soupy and the rapidest should be thick and fluffy.

Fig. 5-1

Step 5: Pour more cement on top of your drive but don’t go overboard. Any more than 1/8th of an inch the drive will be too big. If you want to put this on a lanyard then place a straw in the end of the mold. Allow cement to set for ~half hour to hour for rapidest and 3-4 hours for SL.

Fig. 6-1

Step 6: Check to make sure that cement has set. If it has go ahead and un-mold your drive and it should look something like [the picture below]. At this point the drive can be handled but DO NOT put it into your computer. There is still water in the drive. As most learned in grade school water and electricity do not mix. To error on the side of caution I would wait at least 24-48 hours before using the drive. It is a common misperception that the water in cement dries up. In reality as time goes on the cement will actually absorb moisture from the air.

Fig. 7-1

Step 7: You can now test fit your new drive. Test it with other USB devices next to it (see below). If the drive is too large to fit in the port or prohibits another device from fitting properly use a file to grind it down (see below). Use caution!!! There is only a thin layer between your drive and the file. You can also use the file to round off the edges or shape the drive any way you please. You can also paint it if you like. Your new drive has a compressive strength anywhere from 4000-7000 psi and flexural strength 200-500 psi. This means that you can run over your drive with a car and it should be fine. Try to break it in half like a pencil will be fairly easy.

Fig. 9-1

Fig. 8-1

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Submitted by replica watches (not verified) on Tue, 06/29/2010 - 11:51am.

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Absolutely spectacular! Way

Submitted by brandy (not verified) on Wed, 05/21/2008 - 8:33pm.

Absolutely spectacular! Way to take high tech and low tech and merge them! Good recycling too! If you have enough cement still left over from the fatburger debacle you should mass produce these, just for the sheer yeehaw fun factor!

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Concrete idea. Did you try

Submitted by OuiDaccord (not verified) on Thu, 01/31/2008 - 1:12am.

Concrete idea. Did you try sealing it with PVA glue or something to stop it getting all dusty?

I prefer wood myself, there are several places you can get em like the Dutch company and www.flashsticks.co.uk

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I like this drive and will

Submitted by Tony James (not verified) on Sat, 02/10/2007 - 7:38am.

I like this drive and will be featuring it on my site at www.noveltyflashdrives.com

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Kudos for finding creative

Submitted by amy (not verified) on Thu, 08/10/2006 - 7:19pm.

Kudos for finding creative uses for the left over cement pieces from the Fat Burger incident. Great work!

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Yes and no. Let start off by

Submitted by Matt (not verified) on Thu, 08/10/2006 - 11:53am.

Yes and no. Let start off by reinforcing this idea, you can make the drive as large or small as you desire. The original case design was very poor. Imagine the cement drive being 1/4 inch thicker on each side. This would prohibt the use of the bottom port seen above. By encasing the drive in cement I am able to reduce the thickness, allowing the drive to fit properly. I also wrote this article in response to "lexar memory stick mod" in which strength was a major concern.

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This I don't

Submitted by JadedEvan (not verified) on Thu, 08/10/2006 - 10:28am.

This I don't understand:

"The case protruded so much that if you tried to plug in another USB device you would have to bend the port just to fit it in"

Didn't encasing it in cement in fact just make it larger and bulkier, thereby compounding this problem above?

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The drive really isn't all

Submitted by Matt (not verified) on Thu, 08/10/2006 - 5:37am.

The drive really isn't all that much heavier. The drive is not being supported at all by the lower USB. The photo is from a downward angle and gives the illusion that it is being supported. I haven't really even finished shaping it ethier.

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Isn't it now so remarkably

Submitted by saimhe (not verified) on Thu, 08/10/2006 - 2:28am.

Isn't it now so remarkably heavy that it still can break a port on your $1000 laptop? (The photo already shows signs of need to support the other end of that brick.)

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Crazy people!!!!

Submitted by LOTTARO (not verified) on Wed, 08/09/2006 - 10:17am.

Crazy people!!!!

reply