Disk imaging

Tools of the trade

One of the essential tools for the retrocomputing hobbyist is a disk imaging computer. The machine is used to write disk images to physical media, as well as to archive existing disks. Unless a dusty old pile of floppy disks comes with the vintage computer, a disk imaging workstation is needed to get the machine running when it's "cold metal" with no software or OS available. 

The approach to making new disks depends on the target vintage hardware. I've focused my efforts on Apple IIs, CP/M machines (an IMSAI 8080 and Osborne luggables), a TRS-80 model III, and early compact macs. Here, I describe my disk imaging workstation that reads and writes FM and MFM encoded disks for my IMSAI, Osborne, and TRS-80 machines. It reads and writes 5.25" and 8" soft sectored disks using Dave Dunfield's ImageDisk program. Apple computers use a GCR encoding scheme, and the disks are incompatible with FM and MFM formats found on CP/M and later PC systems. In this case, tools like ADT-Pro can be used to bootstrap a machine over the serial port and use the computer to write an initial disk, then transfer subsequent images. The imaging computer can be any modern or less modern computer with a serial port (including USB) that can run the ADT-Pro software. For early Macs, no such tools are available. For these, I've used a "string" of machines with overlapping capabilities, for instance, by writing an OS 6.0.8 disk image to a G4 Mac that could boot OS 9, transferring it to an ethernet-equipped LC III via AppleTalk, which was then used to write the 720K 3.5" boot disk for a Mac Plus. 

A disk imaging computer is a bit of a retrochallenge in its own right. While some modern hardware exists for reading and writing old disk formats on aging hardware, a straightforward and pretty inexpensive approach (aside from your time and [dis]inclination towards acquiring more stuff) is to use a machine that hasn't quite reached a vintage state. My disk imaging workstation is a Gateway 2000 Pentium 166 running Windows 98.

Gateway 2000 P5-166

I started with an old PC that was pulled from a dusty storage area at work.  The machine had the following installed:

49152 KB RAM 
2.56 GB IDE HD - Western Digital Caviar 32500
MDL: WDAC32500-00H
P/N: 99-004218-000, CCC: H0 5 DEC 96
S/N: W1360 031 8460
two FAT 16 partitions: disk3s1, disk3s5
ATAPI CD-ROM
3.5” DISK
BIOS is an American Mega Trends (AMT) 1.00.05.DQ0T copyright 1992. 
FDC is on the MB and FD cable is universal (both pins and slot)
FDC controller is SMC FDC37C932FR
MB part no. MBDPCI030AAWW may be “Intel Mailman motherboard”
Date code 12/18/98, S/N 0006300888
From http://63.66.78.2/s/MOTHERBD/SOLECTRN/SAC061AA/MC061ATC.shtml
Info from: MBDSAC061AAWW - Intel® P5-166 Integrated MB

Gateway site— 
Desktop Intel® 180/166/150-MHz Motherboard Support Docs by product:
http://63.66.78.2/support/supinfo/index.asp?pg=2&file=dt_mot095.html

PCIset SB82437VX, L6414653, (c) 1995
ATI 3D Rage II video chipset
Windows 95 installed (4.00.950A - first service pack update of the OEM)

My target disks were initially 5.25" single-sided, single and double density, so I needed an appropriate disk drive. Luckily, I found a 360K TEAC FD-55BV-221-U half-height drive (S/N 390676) in the same storage closet as the PC. 

The machine was packed with dust. I cleaned it out and unseated / reseated the memory. The initial boot resulted in 3 beeps (bad RAM) but reseating the RAM allowed it to boot through the memory check up to “keyboard not attached”. The PSU checked out at about +5V (actual 5.2) and +12V (actual 11.8). The power switch does not make a great contact. The plastics are brittle and yellowed. After finding a PS/2 keyboard and mouse on a high, forgotten shelf at work, I could boot into BIOS, but booting to the HD seemed to cause issues (hang or maybe I wasn’t patient enough). BIOS had the correct date (!) which means that the battery had kept the clock going. It had lost about 10 minutes in the span of almost 20 years. 

The machine's FDC is an "IBM PC/AT, PC/XT, PS/2, Plug-and-Play (PnP) Compatible Ultra I/O Controller with Super I/O, Keyboard Controller and Real Time Clock". Sounds awesome. Using Dunfield's TESTFDC program, I confirmed that it could read and write single-density (FM output) at 250 kbps and double-density (MFM) at 250 kbps disks with the TEAC drive

At some point, I'll have to add some info on:
  • Installing an SINTECHI SD->IDE controller, 2GB 150X Sandisk SD card, and 44-pin to 40-pin adapter to connect to IDE cable. I used this as a replacement for the aging (and loud) Caviar hard drive. Works like a charm. I now love 90's computers with solid state storage.
  • Installing Win98 to the SD. It had been a long time since I had installed Windows anywhere except a VM. I had a classic bootstrapping problem trying to write the floppy boot disk to boot the installation from a cd-rom. Lovely.
  • Adding and Adaptec 1542SC controller. This is an ISA bus SCSI card with a pretty powerful FDC—one that can read and write single-density (FM output) at 250 kbps,* double-density (MFM) at 250 kbps, and double-density at 250 kbps with 128 byte sectors according TESTFDC. *Single density mode was broken on some boards. The National 8477 and Intel 82077AA used in the cards have the same pinout, but Intel broke single-density with the AA-1 revision. See the VCFED forum discussion here.
  • Installing a USB card to make transferring images easier.
Writing images with the ImageDisk program (as well as archiving disks to images) is straightforward and Dunfield provides a number of tools for working with the resulting "IMD" files, including a viewer / editor and utilities for converting to other formats.

8" drive adapter

To use the 8" Shugart 800 drives with the imaging computer, I wired a 34pin-50pin adapter. According to Dunfield's notes on connecting 8" floppies to PCs this requires:

PC(34p)   8"(50p)   Description
            2        TG43                 (see below)
    8      20        Index
    12     26        DS1(PC) -> DS0(8")
    16     18        Motor ON/Head Load
    18     34        Direction            (see below)
    20     36        Step
    22     38        Write Data
    24     40        Write Gate
    26     42        Track 0 detect       All Odd numbered
    28     44        Write Protect        pins are GROUND
    30     46        Read Data
    32     14        Side1 Select
    34     12        Ready

My understanding is that the Shugart 800 automagically switches the write current at track 43. Other drives may need to have this signal provided by the controller. 

My initial attempt to write disks failed. The drive head jerked back and forth rapidly. Then I realized that I had forgotten to wire the grounds together on my adapter. After correcting this oversight, I was able to write two images to two 8" disks. The connector isn't pretty, but it gets the job done.


The Shugart 800 drive is about 2/3 the size of the PC, and probably weighs more.