The 512GB Floppy Disk - Micro SD Storage

Floppy disks can't store much, but what if they could?

I thought it would be really interesting to add storage space to an old storage media that no one will use any more. I had some floppies lying around and thought I'd give it a try! My goal was to make it look as original and unmodified as possible.

Supplies

Here are a few things you'll need for this project:

3.5" floppy disk - https://amzn.to/3Q3No8B
Magnets 1x6mm - https://amzn.to/3vgtLlt
Heavy cardstock - https://amzn.to/3Q0ykbC
Micro SD cards - https://amzn.to/3vmNctc
Cellophane tape - https://amzn.to/3betclG
Super glue - https://amzn.to/3bclpEU
Adhesive vinyl - https://amzn.to/3S5sszP

Some tools I used:

Cricut explore air 2 - https://amzn.to/3PU9slQ
Milling machine - https://amzn.to/3PHKhDi
Dremel - https://amzn.to/3S3qgc1
Hobby razor blade - https://amzn.to/3vjiHnM

Note: I may earn a commission from the links above. If you do buy something, that helps me out and I greatly appreciate it!

Step 1: Take Apart Floppy Disk

The first step is to take the floppy disk apart:

Remove the metal slider at the bottom - be careful to keep the front side undamaged
There is a spring inside pushing the slider shut - you won't need that any longer
The actual floppy disk itself isn't needed

Step 2: Cut the Metal Slider

To be able to open and close the floppy disk, you'll need to remove the back half of the metal slider

I used a Dremel and carefully cut along the bottom of the slider, and kept the front of the slider
After this, I glued the metal slider back onto the front housing of the floppy disk.

Step 3: Remove Raised Features Inside Floppy

In my floppy, there were a few raised features on the inside of the 3.5" circular area (on the plastic housing). I machined those to be flush with the main surface of the housing, but you could use a dremel or similar tool to make it flat.

Step 4: Install Magnets Inside Floppy

I machined pockets in the corners of the lower housing to get the magnets to sit flush with each other once both halves of the housing were closed. The magnets were glued into place. On the upper housing, I didn't machine any pockets.

The pocket depth was trial and error. I machined and tested several times. Make sure to go slowly and avoid breaking through the plastic housing!

To install:

With the magnets glued to the lower housing (in the pockets), I put the upper magnets directly onto the lower ones, added some glue to the top of the exposed top of the upper magnets, and then put the floppy together - easy alignment. Give it a few minutes for the glue to dry.

Step 5: Cut the Internal Divider Parts

There are two main parts that hold the micro SD cards:

The dividers (heavy cardstock)
The vinyl adhesive backer

I cut 4 identical dividers (total thickness should be 0.040-0.050") on my cricut, and then aligned, stacked and glued them together using the disk alignment plate (3d printed) and super glue. The disk alignment plate is removed once the dividers are aligned and glue is on them.

I used a few books to smash the dividers flat during gluing. Find something heavy and flat to use, otherwise the dividers may not sit flat and might not let the floppy disk close all the way.

Once they're glued together, you can add the vinyl adhesive backer (sticky side up) to the divider stack. Then, that entire assembly can be glue into the bottom housing of the floppy disk.

Step 6: Add a Hinge

I used a lo-fi method for a hinge - cellophane tape.

With the floppy disk assembled:

I added tape in the upper area - wrapping from the front, over the top and to the back - making sure it was wider the the recess in the back
Next, I trimmed the tape with a hobby razor, to be flush with that recess in the back. It gave it a nice clean appearance.