So - the hardware wallet contains an encrypted private key, this key never leaves the hardware wallet. When you want to do an transaction your craft an unsigned transaction on your computer or some other device, then feed the hardware wallet with the unsigned transaction through an SD card and get a ready to send signed transaction back.
Unless someone steals the hardware wallet along with your password to decrypt the private key your bitcoin should be completely safe.
Both hardware and software will be open source meaning you can either create one yourself (~$20 + an hour or two of your time) or buy a completely usage-ready one for ~$30-50.
If enough people are interested I could have something like this done in about 2 months. Might add more features in the end but not guaranteed (or you can add them yourself ).