Waterproof USB Drive(s)
OK, I’ve been a little slow in posting this. Chalk it up to classwork and laziness. Sorry.
Project Background
Anyway, the back story for this project is; about 3 years ago, my daughter (around 6 at the time) accidentally spilled a cup of coffee (no she wasn’t drinking it!) onto a brand new Seagate 5GB USB 2.0 Pocket Hard Drive. I had set a cup of coffee down next to the new drive on the coffee table, and needed to go back into the kitchen for something. I specifically warned her to be careful not to bump the coffee or the table because I didn’t want my coffee spilled. Well, that must have triggered some inborn child-instinct that says “be extremely reckless when told to be careful.”
At any rate, the coffee got spilled and I got a chance to get a look at the internals of my new drive while I was drying it out. While doing this, I got to thinking about how small the microdrive was and how it could fit into a lot of different casings. Of course, I was also thinking of how to better protect it from liquid damage and how I had so many - now less useful, smaller capacity - thumb drives laying around.
I thought that if I could get a small enough USB hub that I could fit that inside a piece of PVC or other sealable container and plug the thumb drives into it. With my new drive back together, dry and ready to go, that’s just what I did! After all I had to figure something out to do with all those old thumb drives!
Materials and Build
I got a USB hub and some other pieces and started to work. Of course, all these parts took quite some time to gather. I managed to get a few left over parts from work (sealable caps from network connectors) and ordered a USB-B jack for plugging in a USB-A to USB-B cable into. I could have easily gotten a smaller, mini-USB connector and cable assembly, but my soldering skills are not that hot.
I ordered a 4-port USB hub (to give you some idea of how old this project is, I bought the hub on ThinkGeek and they no longer carry the hub I bought) which had two stacked 2-port USB-A jacks. I also needed some plastic resin to seal the USB jack. I used a 2″ PVC compression coupling as a housing and a couple of 2″ long PVC pipe sections as end pieces.
I removed most of the housing and USB cable from the hub and replaced the USB plug on the cable with the jack I’d gotten. Then I sealed the jack inside the PVC pipe with the plastic resin. Before I did that however, I needed to close the back of the USB jack with a glue stick gun to keep the resin from filling the jack and making it useless. I still ended up getting some inside, but it wasn’t much as I can still insert the USB plug into it.
In order to get all the thumb drives into the tube, I had to strip the housings from them. I used a thin piece of plastic to separate the drives and keep them from performing their own circuit bending operations on any of my data. I had to scrape some tracks into the inside of the compression fitting in order to get the hub’s circuit board in all the way. The other end of the tube was going to hold another USB-A jack, to be used as a kind of feed through USB port, but as it turns out, I didn’t fill the back of that connector correctly and the resin filled the jack. In any event I don’t think the cable connecting the 4th USB port to that jack would have allowed the hub to fit in far enough to fit along with all the drives. So it’s probably better that I just used it for a 4th thumb drive anyway.
The Cable
I also used a piece of conduit as a cable keeper, so that my USB cable doesn’t get tangled with other cables when in transit. I use this trick, albeit with a shorter section of larger diameter conduit, with my laptop cords too. I slit the conduit or take a ¼” strip longitudinally out of the center (depending on rigidity), neatly bundle the cables (folding in half 3 - 4 times), insert into conduit, and viola - instant portable cable minder.
Software
Well all this is well and good, but there’s a problem I didn’t foresee. That would be what a pain in the but this is to unmount all these devices on Windows. With a GNU/Linux system, you simply right a script to unmount the drives all at once (and presumably put that on one of the USB drives), Windows on the other hand, sucks for this kind of functionality. But there is a half-assed solution to the half-assed situation I’ve put myself in. The command:
mountvol X: /d
Where “X” = your thumb drives’ drive letter, works to safely unmount the volume under Windows (thanks and attribution to Joel on Software), but doesn’t solve disconnecting Windows from the device (you still have the little “Safely Remove Hardware” icon on your system tray). So you need the DevCon tool available here. Now you can use the mountvol command and:
devcon remove @usb\*
Conclusion
Hot, no? Actually yes, this set up does get pretty hot after a while. I guess that’s a drawback of having this in a sealed container. Another drawback, I’ll never be able to take this on an airplane… :(
If you’re looking for something to do with all those old USB drives that are getting exponentially smaller with every passing day, then this might be a solution for what to do with your old drives. But I think the next time I do this, I’ll use the left over clear resin and do something a little more slick, like Russell Jones, and encase the whole shebang in a clear plastic block.
