How do you make/redeem a physical Bitcoin?
Making a "physical bitcoin"
Run Bitcoin -QT
Go to the console (youtube this)
Dump the private keys (youtube this)
Print the private keys to a peice of paper, make it easy by adding a QR code.
"Redeeming" a physical bitcoin.
Run Bitcoin -QT
Go to the console
Import private keys (youtube this)
Shouldn't be more than 5 mintues of youtube. I forget the commands of the top of my head. I have them written down, although I am sure someone could just edit this and fill them in for you.