sorry folks looks like the server screwed up my posting and i'll have to post my idea for home brewed 5.25in floppies all over again (the post eventually appeared several hours later so i deleted it) ok so where to start (*light bulb appears over head*) i got it if you have a 5.25in floppy get it out and look at it you'll notice that its pretty simple the first part you will notice is the plastic envelope enclosure thing which is just a single piece of folded plastic with some holes cut in it, just below the surface of the enclosure is a fabric or paper dust trap that keeps the disk debris free and finally comes the hard part the disk each disk has 3 components the iron oxide powder, the disk, and the binding glue stuff the holds the powder to the disk. now here is my crude theoretical unproven construction process 1. cut out the enclosure(i'm thinking a material like plastic card stock might work) (probable impossible by hand put it under a laser cutter or watter jet if you have one) 2.use 8 dabs of glue to glue the dust trap in place on the side of the enclosure that will come in contact with the disk 3.spray some adhesive onto the disk and bury it in iron oxide powder 4.remove the excess powder and spray it again with adhesive 5.carefully put the disk in the enclosure and fold the enclosure around it gluing the enclosure shut 6.stick it in your floppy drive and format it i'll have time to try this myself this summer until then feel free the criticize and question my sanity just PLEASE don't suggest buying disks from e-bay, thrift stores, flee markets, online, or any where else for that matter

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According to post time, your floppy thread popped up 1 hour before this one.
it wasn't there when i made this post or last night
its gone now
Kiteman9 years ago
I remember, many years ago, Tim Hunkin of "Secret Life of.." used rust on sticky-tape through a reel-to-reel tape deck to record his voice.
now that is coool!
now all i need is an instructable for making a reel to reel machine (i think i'll save that one for after i make the light pen)(its going to be a big summer =D)
PKM9 years ago
The problem you would most likely have is that the oxide coating on the disk would have to be very uniform for the drive to be able to read/write it and not corrupt or miss any parts out. If you had the actual disk you could easily hack a new enclosure for it together (I did this back in the day for my BBC model B) but I'm 99.99% sure you couldn't make the actual magnetic disk without some fairly sophisticated stuff that would be harder to obtain than a 5.5" floppy in the first place.

If you had, for instance, a damaged floppy with an intact magnetic part you could make a new enclosure for it, maybe even trim the magnetic part from an 8" floppy down to size, but I doubt you could make a new one from scratch. Feel absolutely free to prove me wrong, and post an instructable if you ever manage!
clasic_traveller_diehard (author)  PKM9 years ago
theres one way to find out what special equipment is needed to mass produce floppies dose any one have a picture, diagram, or video of of a floppy factory or Assembly line? WAIT A SECOND YOU MADE A FLOPPY ENCLOSURE BEFORE!?! could you make PLEASE an instructable for making a floppy enclosure. enclosure?
NachoMahma9 years ago
. Getting the jacket open is not a problem - just slit the edge with a box cutter, Xacto knife, &c. . Do not apply any pressure between the modified dust trap and disk. . The iron oxide on magnetic media is not exactly rust. . I doubt if you'll be able to get a usable coating on the disk. . No need to reseal the jacket unless it will be getting some rough handling. Use "Scotch tape" if you just have to reseal it. . Neat idea, but not practical. I suggest NOT using a drive that is mounted in a PC cabinet - you'll likely have oxide, "glue," and Mylar flying everywhere.
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