Disk size solution !?
I don't know if this has been suggested before
so don't flame me ;-)
There is a way to format 3" 1.44 floppies to hold
1972 Kbyte. This is an 'old' DOS program from 1996
and it is -very- compatible with old computers!
And yes, the source code is afailable.
The program is called 2m an you download it from:
The zip files you need are 2m30.zip (250K) and
I can't oversee how difficult it is to build this
in but I think that some die-hard coders can do
this with minimal patching ;-)
Hope this has been helpfull,