Replicating a "black box" and actually understanding it well enough to make a major functional change, like using a different filesystem, are two very different things. I believe that I can replicate the original functionality, or at least document it well enough to be extremely helpful. I don't know enough details at this point to tell exactly what modifications are feasible; a lot of things will probably end up remaining unknown and just repeated from observations. It seems to me that if there is a 20MB volume limit with this interface, and a limit of 2 HD20s, at least some attempts to provide an emulated second HD20 should be worth investigating.
I have a Willem ROM programmer that supposedly can dump the 2764 ROM chip inside of the HD 20. Given that it's only 8 kilobytes, disassembly should at least be somewhat feasible and should shed some light on the Rodime and floppy interfaces. Once dumped, I shall certainly share the 8k file for others to poke around in. Theoretically, we can determine where the Z8 starts execution and disassemble from that point. From there we can determine what register is what, which ports correspond with what hardware, and form up all sorts of cool theories.
If we crack the external disk drive interface, we can build a new board that converts those signals directly to flash. If we crack the Rodime interface, we can build a new board that converts THAT to flash. Both have advantages and disadvantages.
Cracking the Rodime interface allows us to continue using the original controller board and its daisy chain port, the most authentic solution, and maybe the easiest. Cracking the disk drive interface allows ANYBODY with a ROM burner and a soldering iron to build an external disk drive port hard drive with a few affordable parts, but replaces the original HD20 interface board. More hacking is required to provide the daisy chain port, and in all honesty, that part is likely to be skipped in all of the excitement unless it's fairly straightforward. I suspect that the complete replacement version is low-power enough to be powered off of the floppy port.
We have to disassemble the HD20 a bit before we really know which direction to go with this. I imagine that I will have the drive in a week or so. My favorite microcontroller board is loaned out at the moment, so it may take a bit to analyze signals. Stay tuned!