The most you can cram on a DD floppy

[Piru]

I already tried powerpacking all the large executables before adding them to the lzx archive, but surprisingly it made the lzx archive BIGGER. I guess the lzx compression works better on non-powerpacked files.

You're surprised? Uh, come on, this is obvious. You can't really compress data forever, and esp trying to compress already compressed data almost always results in larger file than the original compressed one.

And btw, PowerPacker isn't that good packer. LZX is way better.

[Piru]

The most obvious way is to have the first track as regular 11 sectors per track, then use diskspare.device method to store 12 sectors per track for rest of the tracks. Also use the extra 2 tracks having total 82.

This will give you 983KB per floppy, but is quite tricky to implement (mixed track format requires some special code).